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ENGINEERING C o
JAN. 0 6. i9.97 KILN HEATING UP TIME oitte-17 '2- 1/-Q-
PROJECT
At the time of kiln heating up, it is necessary to pay attention to the following
items.
(1) To avoid mechanical troubles of kiln shell, tyre, roller metal bearings,
etc.
(1) For new kiln, it is necessary to consider the drying time for castable,
burning down time for cardboard spacer (installed for expansion
allowance), thermal expansion of refractory, balance of kiln
revolution by 180, etc.
-1-
ONODA ENGINEERING CO., LTD.
The non-compliance with the above two items during heating up will
lead to refractory troubles and some other troubles (such as unstable
condition inside the kiln, raw meal flushing, overheating, clogging of
cyclones, etc.) which may occur after raw meal feeding. Even if there
is no apparent refractory trouble during heating up, there is always a
danger of causing serious damage to refractory.
2
ONODA ENGINEERING CO., LTD.
(3) When there is rapid rise in temperature during short time, the newly
lined refractory (without coating), particularly the refractory in
burning zone will be damaged due to thermal shock, thus leading to
unstable operation condition of burning section.
(4) Others
ONODA ENGINEERING CO., LTD.
For example,
0.) Report concerning damaged grate plates ( 25 Dec.'97 by Mr. Kimura, Mr.Ujikawa )
(Z Modification proposal during kiln shut-down from 21 Dec.'97 to beginning of Jan. '98
( UBE letter ; A/N - 234 on 24 Dec. '97 )
Kiln
power
(kW)
The most problem of the present kiln operation is that the kiln burner flame is " too short ".
In this case, the following problem occur.
(1) Kiln brick trouble around 7m-12m from kiln discharge end
Clinker telrnperature at the kiln discharge becomes high, then it causes the grate damage.
1250C
The present operating condition of CFIC kiln is "the short flame condition of kiln burner" and
"the high max;mum temperature".
In this case, free CaO is high and the volmetric weight ( V.W. ) of clinker is high The brick
problem ( about 7m) is caused by the short fl.nie condition.
15 Dec Kiln power Kiln speed Kiln burning Kiln torque Red river
zone 12nip.
r N4
1450 /
1-z 00 on i C. -t) ec.
\_ %I/ r ftd----
1400
at 1340C 6.1 Fe 203 + MgO R20 = 6.1X 3.16 + 0.87 + 0.47 = 20.6%
at 1400C 2.95 Ae 203 2.2Fe2 O 3 + MgO 1- R 20 = 2.95 x 5.34 +2.2 x 3.16 +0.87 -4-0.47
= 24.1 %
at 1450C 3.0 A(. 203 + 2.25 Fe203 + MgO + R20 = 3.0 x 5.34 + 2.25 x 3.16 + 0.87 +0.47
7 24.47 %
Normally, 24_5% of liquid phase id desirable figure.
4thie
CooQer
jh Co.se of S/tort fame, di'iiker teinrerafore
is 191A 1 akic( &Ae ic'ttiki'o( rAase ineveAcec,
r
cooffria r( _.,_
T4E/i, efi-Ec I. o i- Cx irl ker becomes
wors-e. pier lore , v-a-te olan-,75 eas,1/
occukv-s,
'7. Heat Flux
5
Heat flux means quantity of heat trasfer,
(2) Especially, the monitoring of kiln burning zone temp. ( TBZ) is quite important. 7
In the most of ONODA cement factories, the temperature of discharged clinker from the
kiln end is monitored. Then, such modification is recommended.
(;3) Average temperature of discharged clinker at kiln end in ONODA factories is 1350C.
The reason of" Brown color clinker /1 is low MgO content in clinker.
( MgO content is 0.74% in CHC clinker. )
Mr. Kimura experienced " Brown color clinker" in a cement factory in China.
Finally, this factory decided to feed dolomite ( as adding MgO) in raw material.
High
(Brown r)
b value
low
(blue )
- Change of the length of kiln burner flame ( from short flame to long flame )
- Change of fuel combustion ratio of SC / kiln ( Increase of kiln burner fuel )
Howere, a high temperature position of kiln shell ( 440C) is observed at 7.6m from
discharge end. Therefore, change of operation should be done very carefully.
The fuel combustion ratio of SC/ kiln is decided by a de-carbonation ratio of raw meal ( at
the inlet of kiln ) and free - CaO content in clinker.
In case of the consideration of fuel ratio of SC / kiln and De-carbonation ratio of raw meal ,
not only the . SC fuel, but also the tertiary air temp. shall be taken into account.
Total heat value of SC = SC (fuel) + ( tertiary air temp. x tertiary air volume x Cp ( specific
heat air ) )
In case of low temperature of tertiary air, fuel amount increases.
OD Relation between the vonietric weight ( V.W ) of clinker and tertiary air temperature
(0 The cooler width control in ONODA plant is done by blind grate, not by castable like CIIC.
(.4 In case of width control by castable, cooling air leakage occurs between the clinker bed and
the castable (r41,1- t 0 nett- r--,9.e)
[A.r1
,6/ = Q . s- O. 6
(3) Control of cooler
In orderix) know the thickness of clinker bed, the following method is recommendable.
In order to look inside of cooler of 1st 4th chamber, installation of additional inspection hole
is recommended .
Cooler Narrowin
/ / r
In ONODA's plant, narrowing is made by
blind grate.
it
hn4
A ir
ct;r
In case of narrowing by castable
/j7
-
/ / T.
( as present CHC cooler ), air goes
through between the castable and clinket bed.
Cas-ta e
Cooler
Efficiency
Heat
Consumption
Kcal / kg.c1
To goo Ro O
Tertiary air temp. ( C )
dinkr ir o9rstribt"tior, of
Coo
- re r tr, meter
-- riird e
_------ * -
I 11
150
1 110
100 _- , /___
&S-
'1 00
0
50
0 Liu
10/110 11112111 3 1 1211 51170 9111517 1011 1.11 1111210
3/1 211 31170 911150
1 , ,
hvi i) 1 1) 1 i rok-e7.
c. i' 1111 /->TiFf10,111; 1. 1 1 1 fq. Ur111 o fj i kl:c17 (VA
2. 20
2. 15
( ti n'Acr cri
2. 10
2. 05 Rte' 2
2. 00
11112111 31170 911150 ; 1011121 11)12111
3/1 20 0
3 11'0 9111511 10)1111
11 - Ca O
1. 5
O. 5
0
311 20 321711 9111511 1011 1 H 11 1 12111
v'c Irvin
I- )1/9 VS
1750
Ock
1700
1 650
1000
'
e.,
Id:1550
- JZt
1500
1450 7,11 A
IV CAS
1400
50 60 70 Bo oo 100 Io
I- )1, 9 / )1:, IfThlia()
Te-'4-c 1 h CtINc,
<F,Ax3).1 ,ri>
441,
Poi Hand Cement
TEST CFI VITICATE E Clinker
Conlract,l40. Dale
Type . : Clinker Supplied lo
Sampling Dale
v- ^ tr-9ec
Qu Inlay
Lot Ito. i Vessel - A ve vole
CHEMICAL COMPOSITION & MINF,LAL CONS'ITIVENT
Requirements Results*
Los on ignition (W' ) max. 0.47
In s~lilhl~IZ~si~luc (%) max.
SiO z I y';', 22.06
Al z03 (`;"(), 5.32
13&:*.y. 81; X. ((70 3.36
64.97
MgO (rg,) mar. . 0.74
SO3 (VC') 111 a X. 0.38
K2 0 0.63
Nai9 C;f0)' 0.19
Total alkalies (as Na 2 0) ' 0.61
Fro Ca()I M a X. 0.76
C3 5 I 55.21
e2S (:)c(:)) 21.60
C3 A (To) 8.41
C4 A (%) . 10.22
li
PITYSICAI., PROPERTIES
*Tet TCVN
Oft
lion Clung - SI Hung
Chief-
()wilily Mgt Sec.
Explanation of Kiln, Cooler Operation by Mr. Kimur
No 2 : Change of kiln speed and burner position, Kiln passage time
on 18 Dec.'97 at 10:00 11:45
CO The present kiln speed 2.60 rpm at 260 t/h Kiln feed rate is too fast.
According to the attached graph, the target of material filling rate in the kiln shall be 6%,
then the target of kiln speed is 2.34 rpm at 260 t/h kiln feed.
In case that the material filling ratio in the kiln Is changed, the condition of falling down clinker
on the cooler is also changed.
(4) Material passage time in the kiln 22 min. ( short ) ...-s. - I.:, %.." ,
a. 6
( 2
Yir)6 ;. 1 6 2 16
2.6
147 207 2_, cg
2. c)
22
185
30
1. 2 0
/. 77
7a
(. 6 /.62
1.54-
1 .4
- 0A -feed zoo 270 2-2 9 230 .240 2 SO _aeo 270 280 E_-`71,3
icrrdtwfioil, 3 00 > 60 0
f.-)00 T +A1.3
raw wts.r.ot,/
/ t- cAin,4e-
17
4. Operation data on 17 Dec.'97
More than 40 min. Kiln condition becomes dusty. Red river occurs.
(t) The red river of CHC occurs in the condition of the passage time of less than'25 min, and
high temperature of clinker discharged from kiln.
The red river of CHC is not the case of long passage time of more than 40 min.
6. Target of kiln speed, kiln torque and the burning zone temperature ( TBZ )
The current operating condition is show in " " line, and it means high
burning zone temperature and short burning time ( short flame ).
The operating condition shown in " "line is desirable, and the current
condition should be changed to " " line .
Condition
Then,this condition is OK
A,B is each area above 1420C ( A is current condition, B is the condition after change of kiln
flame. )
L : Kiln length ( 76 m )
C4 material
temp.
Burning zone
temp. ( TBZ ) IM=111/1111111
Time
1. Status of meeting
(1) Kiln burner was inserted into kiln by 100rum on 18 Dec. at 14 : 30.
The burner position before insert was just the kiln end at hot condition. After insert
of burner, the burner front end is 100mm inside of kiln in hot condition.
Le ri e A ,e
Coating length was changed from 15m to 16m. Hf ( at = 16m ) = 75.7 x 15 = 71.0
kcal/m 2
If Hf is kept constant, fuel shall be increased as follow.
When the butter position is changed or burner flame shape is changed, the most import
check points are above mentioned coating end position ( coating length ) and the
position or coating ring .
If H.NI fluctuates as 2.15 0.04, kiln operator can not control the operation.
In case ,of fluctuation as 2.15 0.02 which has continued from yesterday, it is very
difficult to keep good operation.
In the worst case, it may cause the melting of kiln brick.
(Ii) Kiln heat load of cross section heat load is calculated of follow.
Heat load = 7,200 kcal/kg x 7,400 kg/h 3.9 x 10 6 kcal/m2 h
7C / 4xD2 t 1 3,0)
D = kiln inside brick dia = 4.15m
The average figure of kiln heat load in Japanese cement fectories is 5.0 5.2 x 10 6
2h. kcal/m
The, figure. of CHC is lower than the average of kiln in Japan, thus even if ELM
flactotes, there is not concern about melting of kiln brick.
But, low heat load cause high Free-CaO in general. Thus, the heat load is
recommended to be increased more. If the kiln fuel is increased from 7,400 kcal/h to
7,900 kcal/h, the kiln heat load is increased from 3.9 x 10 6 to 4.2 x 106 kcal/m2 h.
21-
The kiln heat load about 4.2 x 106 kcal/111 2h is recommended to keep Free-CaO in a
target range.
(E)) In Tsukumi plant, the target value of ITN; deviation ( clinker basis ) is 0.02.
(4) Whtn R. 1W mill is stopped, kiln dust collected by EP ( high HM dust ) should be
stored in kiln dust bin.
After Raw mill start, the kiln dust is gradually discharged, and is mixed to raw meal.
(After finish of this day's meeting, it is confirmed that kiln dust is stored in the kiln
dust bin from 2 months ago. Operator forgot this action only on 18 Dec. )
For rough visual checking method is described in Cement Data Book. ( It is attached to
this report. )
8. When S.M is decreased, the burnability of raw meal becomes good. ( It becomes easy
burning. )
Free
CaO
711100IMII
Before 16 : 15 16 : 49
action 19 Dec. 19 Dec.
After the action on 19 Dec. ( making kiln burner flame longer ), kiln condition became
stable and the following points were observed.
(4) The color of red river ( which is observed from the tertiary duct on 4th chamber of
cooler ) became dark.
According to the identification sample (color vs temperature), the color of red river
was changed from " light orange red : about 950 C " to "orange red = about 850C).
,
a CdFt D/Yi trem t)71 2r/Dec '9'1
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schen C'fensch issen. Die Ausmauerung on 1Ther- highly labor consuming, job, requiring specially
gangsz Lien ist kompliziert, arbeitsaufwendi und shaped refractory bricks. A kiln shell shaping which
verlam t Spe7dalforinsteine. Eine besonders is particularly disadvantageous, Is the narrowing of
F)rmgebung, die mehrfach angetroffen wind, ist the kiln's discharge end; this results in partial cooling
lie Ve -engung der Auslaufzone des Drelic.fens ; dies of the clinker in the kiln and in a rapid wear of the
(Wart z t teil .veisen Ktahlung des Klinkers in, Olen refractory in this section. I
und zu; schnellen Abnutzung des Ofenfutters ,n die-
sem At schnitt_
Sowohl praktische Erfahrungen als auch theorctische Practical experience as well as theoretical delibera-
Cfherlegungen ftihren zur Erkenntnis, dad der Dreh- tions lead to the observation that rotary kilns without
ofen ohne Einschniirungen bz-w. Erweiterungen die constrictions or enlargements represent currently the
derzeit g , instigste Ofenform darstellt. Die Dreiirohre most useful kiln construction. The ;hells of modern
der mr dernen WarrnetauscherOfen weisea hereits preheater kilns already sh'c)w uniformity throughout
durchwe.gs einheitliche Querschnitte auf. Schtechte the cross-sections. Unfavorable experience with
Erfahrungen mit Drehofen verschiedener Quer- rotary kilns of different cross-sections, prompted the
schnitte veranla3ten die Zementindustrie der Sowjet- cement industry of the SOviet Unio). to build rotary
union, rur noch Olen mit einheitlichem Durchmesser kilns with an invariable diameter exclusively.
zu bauen,.
Fig 19.3. g
Schematic of the de ree of kiln filling
Ofenfrillungsgrade schwanken in den Grenze i von Kiln filling degrees fluctuate within the limits of
etwa 5 UnebbAngig vora Ofenclurchnies er ist about 5-17 go. Independent from Ulf- kiln's diameter,
der Fulliulgsgrail hit- die verschiedenen Wertz des the percent of filling for the different values of the
Zentriwinkels rc wie centric angle a is as follows;
384
.1
19.1. Ausfri nrungsformen uas Drehofens 19.1. Types of rotary kAns
10'0'
.7.
Ins ide kiln dia me ter
10 20 30 35 lin
Drenolendurchsotx
gen zwi ir- hea 2 und 6 Vo. Meistens triff:, man jr loch Most kiln slopes are between 2 and 4 olo to the hori-
Ofen mit Neigungen von etwa 2-4 Wo znr Hod? )rita- zontal. Originally, rotary kilns had higher slopes with
ln an. Eirsprunglich hatten Drehofen qn56ere 1fei- lower revolutions ranging (rola 0.5 to 0.75 rpm. Lower
g , ingen lei niedrigen Umdrehungszahlon von -,tv a kiln slopes require higher numbers of revolutions;
05-0.75 LUrnin. Geringere OfennuiguLrg erk dert this has the benefit of better mixing of the kiln feed,
e i ne ho'wre Drehzahl ; dies hat den Vo;teil, dad das together with a more intensive heat exchange. Lower
Ofenmaterial besser gemischt und eLrem intensi- slopes also permit higher degrees of kiln filling or of
veren Warmeaustausch ausgesetzt wird. Nlan kiln load. Practical experie'r, :e resulting from kiln
erreicht auch mit geringerer Neigung hohere )(en- operation shows that the following kiln slopes yield
hillungs grade. Aus praktischer Erfahrung resuliert, the corresponding average kiln loads; see table 19.1.
daft den folgenden Ofenneigungen im prakti; :hen
Ofenbetri!b optimal erreichhare Ofenhillungs; rade
entsprechen; siehe Tabelle 19.1.
:kndererseits wird behauptet, dab der Clenfrillv ngs- On the other hand, it is said that the kiln load
grad vorn Verhaltnis der Lange (L) zum 1,?nrc:hrn sser depends on the length (L) to diameter (D) ratio of the
(D) des ()fens abhangt. NaBdrehofen mit 'einem './D- kiln. Wet process rotary kilns with an LID-ratio of 40
Verhaltr is von 40 und darriber weisen Fullungstrade and more, show kiln loads of tip to 17 % 0761. In any
his zu 11 0/o auf [1761 dedenfalls bestim nt die lei- case it is the rotary kiln's slo'pe which determines the
gong des Drehofens in erster Linie den ngs- kiln's load in the first place; in addition to this Is an
g[ad, wobei ein steigendes L/D-Verhaltnis den Fril- increasing L/D - ratio a factor, v-hich can contribute to
lungsg -ad noch erhohen kann. the kiln's higher load!
fm praktischen Ofenbetrieb soil ein Frillungsgrar' von In practical kiln operation the kiln load should not
1:1 A) nicht uberschritten werden, da 1rohere ['CIL exceed 13 ,/o, since higher kiln loads impair the heat
tungsgrade den Warmelibergang versddr chtern. transfer.
385
3l
3. Installation of kiln burning zone pyro meter ( 24T72 ) at the side of kiln firing hood
5. Relocation of grate plate thermometers to check the clinker bed conditions properly.
CO Mr. Kimura and Mr. Ujikawa prepared a report " Report Concerning damaged grate
plates, dated on 25 Dec.'97 " and submitted it to CHC.
In this meeting, Mr.Kimura explained this report, and summarized the optimization
of kiln and cooler operation.
And also, important items for next kiln operation was explained to CHC.
(.0 When Mr. Kimura came to CHC site, and checked operating condition, the kiln
passage time was short ( 22 min. ) and Frce-Ca0 was high. ( It fluctuated rapidly. )
The damper of kiln primary air fan was cb)sed from 26.8 % to 14.6 %, and tried to
make the kiln burner flame longer on 19 Dec. at 16:50.
(0) After this Ac tion was taken, kiln torque kept high, and Free Ca0 was decreased.
This change of condition are obsered in the graph of " Trend after action " in page
Kiln
torque
70
Free
CaO
II
I . I / I I
1620
\D I
\I 1600
KILN
'72 *---`-' E,c)
iiK RUE
, - Abu
-.',- 15/1-0
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6 10 - IS 22 z 6 10 t, - I 22. - ID 14- IS 22 2 6 10 1
1S/PeC ivDeC 2,0/
ec
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/Dec ikr)
Pressure % chaiisect froir l /8-041 " a$.
().__,._, . t.
QS
ed from, 2,kre
, . 1.--A A N..,-1._ 3-L,, -. ! _ ,,.
1 _ L_
4. Kiln heat load, Coating length and kiln inlet hood temperature
5.0 x 10 6 22 1050
In casc of the present low heat load ( about 3,9 x 10 6 kcal/m2 h ), clinker quality ( Free-
Ca0 ) is not stable
C5 C/c2on(,
Around 4.2 4.7 x 10 6 kcal/m2 h is a recommendable range of kiln heat load for CHC
kiln.
73X
( kArtitil
20rie teiT )
1c16*t livv"vw%
In case that 113Z increase and kiln power decrease ( as above mentioned trend ), it
means that the liquid phase of clinker is increasing. This case is a very dangerous
situation for ttrate plates, because it is easy to be damaged by incerased liquid phase,
In such case, operator must open the damper of cooler 1st chamber fan more for
preventing grate damage.
3t
If the damper can not be opened more, kiln buring zone temperature should be
decreased.
Operator must consider such cases as emergency case, i.e. grate plates might be easily
damaged.
For decreasing kiln buring zone temperature following action shall be taken
- Decrease of kiln fuel
- Open of kiln primary air fan damper to make flame longer
6. Difference of clinker bed thickness between 1st and 2nd stage grate ( Page 5/6 of the
report " Report concerning damaged grate plates " )
The present difference of the pressure between 4th chamber and 5th chamber ( 1st
stage and 2nd stage of grate ) is 150 200mm H 2 O ( = 15 20mbar )
It seems that the thickness of 2nd stage grate is much thinner than 1st stage grate.
In this case, red river can easily flush from 1st stage to 2nd stage of grate, then grate
damage occurs.
The thiekticsS of clinker bed of 2nd stage grate should be same as 1st stage, or thicker
than 2nd stage.
This is a very important matter for cooler operation.
The suitable pressure difference of 4th chamber and 5th chamber can be considered as
about 70mm 14,0 ( = 7mbar ). However, the situation of clinker bed should be well
obsertkd.
( The graph in page 2/12 of " Report concerning damaged grate plates" )
The operation target is kiln torque 75 and burning zone temperature 1500 1550 C.
Temp.
1450C
1250C
In case of the tertiary air volume F I is less than F2, castable damage easily occurs.
Therefore, it is important to make tertiary air flow Fl and F2 equal flow rate. ( It can be
achie'ed by installing pressure gauge and making both pressure equal. )
Ak'fi2v4A,
(A 0
0.3D
F2
if F1< F 2
11 roo----t- of- cas fade
ctamleot,
2 o--DeC
'SYSTEM : i:UNC MENU 20/1)EG/1997 11:33
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_ 24I 8 24:01
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SYSTEM HEAVY LIGET L
FUNC MENU 20/DEC/1997 11:31
113/ 430
TAG- NAME 1 KIND i VALUE 1 UNIT 1 MINIMUM j MAXIMUM I
- - r ! -KILN -`7:.T V = u.nTr'.P _ D 7 :1? _ 7-"__. L. - . / 0 5 1 ,.;;L - - ,-,,,- , ,,-, .
2 I KU N
! 3 1 KL1;
BURNING ZONE
AC1'; END GAS TF!.'P.
TEMP. Dtii
D'.1
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