ONODA ENGINEERING CO., LTD.

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.

(2) To avoid refractory troubles (The refractories protect directly or

indirectly the above components against heat).

1 DETERMINATION OF HEATING UP TIME

The heating up time is determined taking into account the

environment in vicinity of refractory.

(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.

(2) Kiln inside temperature at the beginning of start-up (e.g. ambient

temperature, high and medium temperature at shut down).

(3) Others such as flame pattern, whether or not there is refractory

lining in top cyclone, etc.

Notwithstanding the above, it is most important to comply with the

following.

(1) Burning Section (Preheater - Kiln)

The heating up should be carried out to achieve the target

temperature at outlet of top cyclone, kiln inlet hood and burning zone

-1-
 ONODA ENGINEERING CO., LTD.

as well as balance among these temperatures. The raw meal feeding

is started once the temperature of gas at kiln inlet hood reaches the
target temperature. Nonetheless, the temperature at burning zone
during heating up should not exceed the target temperature to avoid
damage to refractory.

(2) The heating up time should be decided so as to prevent melting down

of refractory as well as to avoid damage of refractory due to thermal
stress inside refractory.

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.

If heating up time is too long (24-36 hours) or too short (8 hours), in

either case, it is practically difficult to achieve a continuous balance
among the three temperatures mentioned above both during heating
up and after raw meal feeding. If heating up time is too long, the
above troubles will be experienced repeatedly but too short heating
time is worse.

Accordingly, the most optimum heating up time is 12-15 hours

which has been decided considering the mechanism of causing
damage to refractory (described hereafter) and to achieve a stable
kiln operation after raw meal feeding.

2
 ONODA ENGINEERING CO., LTD.

2. MECHANISM OF CAUSING DAMAGE TO REFRACTORY

DURING HEATING UP

(1) High temperature of burning zone, highest temperature point,

causing melting down of refractory.

- Too short flame causing overheating locally.

- Also, it is not possible to achieve a balance among three

temperatures i.e. temperature at outlet of top cyclone, kiln inlet

hood and burning zone. For example, the burning zone

temperature may be high while other two temperature are low.

(2) When the heating up time is too short, sudden increase in

temperature will cause excessive thermal stress inside refractory,
thus damaging it.

(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.

3. HEAT DISTRIBUTION DURING HEATING UP

Even if the total heating up time is optimum, the improper speed of

raising the temperature will give rise to troubles mentioned at 2(2)
and 2(3) above.

The bending strength of refractory decreases with increase in

temperature. If the difference in temperature rise between loaded
face and inside of refractory is large (i.e. rapid rate of raising the
temperature), the thermal stress in refractory will increase. If this
thermal stress at a particular temperature, exceeds the bending
strength of refractory at that temperature, then refractory will be
damaged.

(According to laboratory tests conducted by Asahi Glass Co., Ltd.,

Japan for basic refractory bricks, if half of the thermal stress
developed at particular temperature exceeds the bending strength at
that temperature, the inside of refractory is damaged.)

Considering the above, the rate of raising the temperature at least up

to about 800C should be kept as slow as possible (actually it is
decided by stable burning condition achieved at minimum fuel feed
rate corresponding to burner design). In our opinion, the rate of
raising the temperature up to about 800C during heating up can be
kept as 80--i 00C per hour. Above 800C, the rate of raising the
temperature is determined by dividing 1,500-800 = 700C
temperature by remaining heating up time.

For example,

Normal temperature to 800C : 9QC/hour, heating up time 8.5 hours

800 to 1,500C : 700/(15-8.5)=110C/hour, heating up time 6.5 hours
 Instructions for Optimization of Kiln and Cooler Operation
Doc. No : UT - KLCL - 01
Date : 7 Jan. 1998
1. Purpose of this document
UBE invited Mr. Kimura and Mr. Ujikawa ( Chichibu Onoda Cement Co., ) to CHC site from
15 25 Dec.1997 in order to check and optimize the kiln and cooler operation.
During their stay, Mr. Kimura explained much important and useful] matter for kiln and
cooler operation, and also prepared reports. The purpose of this document is to record Mr.
Kimura's various explanation during meetings ( which were written and explained on white
board ) to keep as technical document in CHG.
t)C\wu&O.,A (1 4 47
2. Contents
tit
Explanation by Mr. Kimura ( Chichibu ()noda) about kiln cooler operation
No. 1 : on 16 Dec.'97 at 9 . 30 12:00
No. 2 : on 18 Dec.'97 at 10 00 11:45
No. 3 : on 19 Dec.'97 at 14:00 15:00
No. 4 : on 22 Dec.'97 at 14: 45 16: 30
No. 5 : on 25 Dec.'97 at 14'00 ,,, 16:30
(Explained with above mentioned report "Report concerning damaged grate
plates, 25 Dec.'97")
3. Reference documents
Refer to the following documents which were submitted to CHC together with this document.

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 )

- New grate narrowing

- Installation of kiln burning zone thermometer at the side of kiln hood
- 2 sets of new inspection hole for cooler inside
- Change of location for grate thermometers
- Installation of guide vane for cooler 1st chamber cooling air

(a) Reference training text

(Prepared by Mr. Kimura for a training text book of cement plant in Taiwan )
 Explanation of Kiln, Cooler Operation by Mr. Kimura on16 Dec.'97
No. 1 : Present operating condition
on 16 Dec. '97 at 9:30 12: 00

I. Status of the meeting

- To explain the present operating condition

- To explain some important matter for kiln Operation

2. Kiln torque and kiln speed

Kiln torque Kiln power (kW)

Kiln speed (rpm)

Kiln
power
(kW)

Kiln speed (rpm)

Kiln torque shoidd be observed to monitor the kiln burning condition.

3. Problem of the present kiln operation condition

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.

OO The quality of clinker becomes worse

- Free Ca0 increase (1/41 c
- Voltnetric weight (V.W) of clinker increase AAL
 freSerit" C ond 111'011 0 CHC 3
(VI -t- ern )
Max. tem retoch ,o- e
Temp.
mi- v
1420C

1250C

Om 7m Kiln length (m)

(Kiln out let)

Burning time is short Free CaO increase

Maximum temprature high Volmetric weight (V.W) of clinker is high.

The present operating condition of CFIC kiln is "the short flame condition of kiln burner" and
"the high max;mum temperature".

(Show in line in above graph)

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.

4. Operat ng condition of yesterday (15 Dec.'97 )

Due to the leakage at the pulverized coal transport piping, kiln fuel was changed to 100%
heavy oil conbustion.
The kiln torque was high after changing to 100% heavy oil, then red river was not observed in
cooler.

15 Dec Kiln power Kiln speed Kiln burning Kiln torque Red river
zone 12nip.

14 : 00 221 kW 2.44 rpm 1459 "C 221/2.44 = 90 NO

15 :00 231 kW 2.51 rpm 1491C 231/2.51 = 92 NO

 Kiln tol que Vs temperature of kiln burning zone

Buthing zone Tool-et IS In

_til 15 cirq
f5; 00 on /590
Temp.
1500C 7 7/"'\

r N4
1450 /
1-z 00 on i C. -t) ec.
\_ %I/ r ftd----
1400

Kiln torque 80 90 100

( kiln power/ kiln rpm )

6. Calculation of liquid phase of clinker

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.

,Sh ort an ,,, e

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,

171- ;ek incide

L "Pi A 4-f CoGr6in

V = calorific value of Fuel ( kcal/kg )

m = amount of fuel ( kg/sec )
Heat flux Ilfr , V x m (kcal / sec.m 2 )
ixTcxD
0 In case that the length of coatingt is around 15m 16m, Free - Ca0 is high, or Free - Ca0
fluctuate ( high, low, high, low ).
In this occasion, kiln operation becomes quite difficult. The present kiln operation is in such
conditions caused by short flame.

Free CAO -OtAc -Evcs -tes,

About 22 ,25m of coating length ( ) is desirahble for this size of kiln.

The coating length can be observed by kiln shell temperature scanner.

8. Important factors of kiln operation

Et) Following factors are very important for kiln operation,

- Volmetric weight ( V.W ) of clinker
 6
- Free-CaO
- kiln power ( kW) and torque the prfseht
- TBZ ( temperature of kiln burning zone ) rocitiur,
- Length of kiln coating

(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.

9. Brown color clinker

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.

Ae203 Fe20, MgO SO3 Ap n

-2.,3,
/p,a
. ...2%-, 3

C3S : Ordinary clinker 0.83 0.53 1.04 0.08 1.57

Brown clinker 0.97 0.72 1.08 0.15 1.35

C2S : Ordinary clinker 1.71 0.92 0.47 0.89 1.85

Brown clinker 2.14 1.2S 1.75 1.24 1.71

GAF : Ordinary clinker 24.81 15.45 4.94 0.07

Brown clinker 31.82 5.07 0.54 0.00

The color of cement is effected by C4AF.

Cement color is indicated " b value " in Japan

High
(Brown r)
b value
low
(blue )

1.0 20 3.0 MgO.

 In case of low MgO content in clinker, Fe-2.03 goes to C 3 S and C2 S, and Fe2O3 in C4AF
becomes low.
If MgO content increase by 0.1%, b value degrease 0.5%. ( Cement color becomes blue. )

10. Actual method for change of kiln operation

Or Following procedures shall be done,

- 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.

The target value is ;

De-carbonation ratio of raw meal = more than 90%
Free-CaO in clinker= less than 0.8 vo
The present. de-carbonation ratio is reported about 85%, but sometimes it decrease to
70-75%.

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

V.W of clinker increase -4 Tertiary air temp. decrease

V.W of clinker decrease Tertiary air temp. increase
 8
11. Cooler width control and operation

Reference of cooler width control

CHC China 1 China 2 Japan 1

Clinker 4,000 4,300 4,100 4,000
Production
( t/d )
Kiln D 4.55 4 4.64) 4.64) 4.24

Brick 0.2 0.2 0.2 0.2

thickiless(T)
Non width ! 2,7 2.4 2.4 2.1
control e I (m)
e ti D 2.7/4.15-0.65 2.4/4.2 = 0.57 2.4/4.2 = 0.57 0.55

(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

Ctoier Co4er- w 04 Cory( r- 4

04: Non vtid-til Coerti-oY

,6/ = Q . s- O. 6
(3) Control of cooler

The following matters are important factors for cooler operation.

- Setting of suitable thickness of clinker bed, and keep this thickness

- Control of red hot area of clinker

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

Confirmation of the clinker bed thickness

In order to check the clinker bed

thickness,
it is recommended to install the
0,8m 71 h.- marking brick.

0.6p, ,--,... --,

'',,I / , i / ,
 /0

(J) Cooler efficiency vs Thickness of clinker bed

Cooler

Efficiency

0.6 0.8 clinker bed thickness (m)

- In case that the thickness of clinker bed is too thick, the secondary sintering occurs on the
surface of clinker bed.
- The target of clinker bed thickness is about 600mm.

(.5) Heat consumption vs tertiary air temp.

Heat
Consumption
Kcal / kg.c1

To goo Ro O
Tertiary air temp. ( C )

(0) Monitoring of grate plate temperature

dinkr ir o9rstribt"tior, of

Coo
- re r tr, meter
-- riird e

(11) Cooler efficiency

Cnventional cooler : Normal 55% 60%

In case of good width control 60% 65%
Mulden type cooler = 70% 75%
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 CHINFON HAIPHUNG CEMENT CORP.
TRANGKENI I - MINHDUC - 1111, )/NIGUYEN -11A1PlIONG - VIETNAM
TEL: (84.31) 875 ) FAX (84.31) 875 478

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

Con tires 1tC strenglli

3(tiys
7days
I .
(N/n), ,
28days ) min.
Setting tiMe: (Vicat lest)
set (min)
Final set (min) max.
Soul' lness: (Le Chatelicr) (`ro) max.
Fineness:
Sieve 0.08 nun (%)
Plaine (cin'j); I min.

*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

1. Status c f the meeting

After checking of the present operating conditions, the following matters are proposed.
- Change of kiln speed
- Change of burnner position ( for long flame )
- Consideration of passage time of raw material in the kiln

2. Present operating condition

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.

Kiln kiln burning zone Passage time Kiln speed

torque Temp. ( TI;Z ) in kiln
17 Dec. 75 1550C 22 min 2.60 rpm

5 Dec. 85 1450C 27 min 2.60 rpm

In case that the material filling ratio in the kiln Is changed, the condition of falling down clinker
on the cooler is also changed.

3. Importantfactors for kiln operation

Factors The present condition of CHC

(-0 Kiln torque Low
W Temperature of burning zone ( TBZ ) High
.r) End of kiln coating 15m ( short ) 2 ,, 1, ,....,

(4) Material passage time in the kiln 22 min. ( short ) ...-s. - I.:, %.." ,

V Volmen ic weight of kiln High

Free - Ca0 High
( -7) Temp. Of kiln inlet end Low
V Temp. of tertiary air OK
 in.5icke r-Q,lorcutvvi
kt 0 rn betw e.e ,n Fateal feed tune om ty,

1%.t,t froAi 0 tA. 49

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

Kiln speed Kiln TBZ Kiln

Sift ( rpm ) torque ( Kiln burning zone) passage time

1st : 2.60 75 1435 1576 25 min.

2nd 2.60 73 1400 1597 25 min.

3rd 2.55 80 1407 1598 28 min.

5. Raw material passage time in kiln

Kiln passage time Kiln condition

Less than 25 min. Kiln condition becomes unstable.

30 min, Kiln condition is stable, and clinker quality is good.

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.

The target of the passage time is 28 min 3 0 min.

6. Target of kiln speed, kiln torque and the burning zone temperature ( TBZ )

Target of kiln torque 80 90

Target of TBZ 1400 1500 C

Target of kiln speed is 2.50 rpm as a first step.

Present kiln speed 2.60 x 60 = 156 rph

First target 2.50 x 60 = 150 rph

 /8.
Theorei ic ally, final target is 2.34 rpm x 60 = 140 rph

7. Kiln burner position and adjustment of burner flame (0,Feco

PrRseht et,pet
A / Present- cbnd4isot cAcie / / b(aveh)
Tc nip.
Under the area of 1420C
142.0C
is a cooling zone.
1250C

Kiln length 15m 20m

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 .

After change of operation

Condition

B<A Free - CaO is high.

Volmetric weight of clinker is low .

Then, kiln fuel shall be increased from 42% to 43%.

B=A Free CaO is low

Volmetric weight of clinker is low

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. )

(i) Length of kiln cooling zone

Desirable length of kiln cooling zone = ( 1.5 ) x D = 4.15 6.2m
D = kiln inside brick dia. ( m )
The present cooling zone length seems to bey about 2m only.
 V When the bUrner position is changed, operating condition should be monitored for minimum
4 hours until situation changes. ( Due to large heat capacity of kiln )

8. Raw material passage time in the kiln

T= KxL T = Passage time min. )

DxNx0 K : constant value

L : Kiln length ( 76 m )

D = Kiln inside bri&k dia. 4.15 in )

N = Kiln speed ( rpm ) )t e

0 = Kiln inclination ( 4/ 100 ) kr 110 "Xo

The theoretical value of K is 0.142.

In CHC kiln, T is measured as 22 min by trend chart graph.
K is caliculated by using T = 22, then K is 0.13.

Method of determination T by trend chart

geduce -Peel to -6A
-Soy. 5 ^- 10 m in.
Karl feed
( t/h )

C4 material
temp.

Burning zone
temp. ( TBZ ) IM=111/1111111

Actual passage tinn e

Time

Lictec.ot fr, ate r itd tethrev. 0-6-01-e, /et hoot

-tt
o cool be vsed or cd,ove
 Z2
Explanation_of Kiln,Cooler OperationbyMr,Kimura
No. 3 : Condilion_after 100mm insert_of kiln burn=
_on Mice. '97 al 14:00 15:00

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.

2. Condition after inserting kiln burner ( 100m n

The condition after inserting burner is the case B < A. ( Refer to the explanation of 18
Dec.'97)
That is, Free - Ca0 is high and Volumetric weight of clinker is low.
3. Analysints by the concept of Heat Flux ( refer to explanation on 16 Dec.'97 )
Hf = 7200 kcal/kg / 3600 x 7400 kg/h = 73.7 kcal/m2
x D x-e
D = 4.15 m (;kiln inside brick dia. )
e = 15 in ( Coating length )

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.

7400 x 75.7 = 7890 kg/h

71.0
7890 - 7400 = 490 = 0.5 ton coal/h
 23
Therefore, fuel of kiln and SC ( calciner) shall be changed as follow.
Kiln fuel 7.4 -1- 0.5 = 7.9 t/h
SC ( calciner ) 10.5 - 0.5 = 10.0 t/h
4. Kiln Coating monitored by kiln shell temp. Scanner

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 .

5. Fluctuation of ELM in the kiln feed raw mul

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.

0 The kiln heat load is depended on burnability of raw material.

In case of low burnability material, kiln heat load should be higher.

(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. )

6. The next action for operation

If the lbllowing conditions are fulfilled,
> 2.17
Kiln torque > 70
Kiln burning zone temp. < 1550 C
( TBZ )
Change fuel by the step of 0.1t/h at avery 30 minutes.

7. Mater* filling ratio in kiln

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. )

9. Kiln heat load vs Free-CaO the normal relation is as follows.

Free
CaO

711100IMII

4.2 5.0 x 106 kcal/m2 h

Kiln heat load
 2 5-
10. Action of operation on 19 Dec.'97.

After finish of above explanation, kiln condition is as follows.

Kiln torque = 140kW/ 2.51rpm = 56 ( very low )
TBZ = 1600 C ( very high )
Therefore, the damper of kiln primary air +An ( 24FN5 ) is reduced in order to make
burner flame longer.

Before 16 : 15 16 : 49
action 19 Dec. 19 Dec.

Kiln prim. Air 26.8 A 18.1 % 14.6 % Keep

fan damper continuously

Pressure of circulation 1150mm H2 O 1050mm H2 O 950mm H2 O

flow of kiln burner

Afer above action, kiln power was going high.

11. Operating condition on 20 Dec.'97

After the action on 19 Dec. ( making kiln burner flame longer ), kiln condition became
stable and the following points were observed.

(I) Free CaO keeps less than 0.8 %.

Kiln torque became high

13e1bre Action Action for After Action

19 Dec long flame 19 Dec. 20 Dec.
10 :00 12 :00 14 :00 19 Dec 16:00 22 :00 2:00 6:00 10 :00 14 :00
Free-CEO 1.69 0.86 0.38 0.49 0.86 0.47
(%)
Kilit ' 61 60 62 79 77 75 77 74
Torque

( Refer to attached " TY'end after action. )

(,3.) Grate plates of 2nd row in 1st chamber was heated to red color before action.
( was observed from inspection window under grate. )
Hoverer, after above action was taken, rcd color heat was disapeared.
It meanS that the clinker temperature at kiln discharge end was rather decreased.

(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).
 ,
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6 to Fri IS 1,1_ A I S 10 14- 15

. 22 2 lo b=i-
is/pec 2,_
rvec. 2}6ec
Pre.mAre 'fi gs cj, 47/ked, fro/71 /8-Dmout. 9-0
II A .41 the a f t. 441- c,losect ro-/X6X.
Mt, n! Vri "Te


19. Der Otehofun
schen C'fensch issen. Die Ausmauerung on 1Ther-
gangsz Lien ist kompliziert, arbeitsaufwendi und
verlam t Spe7dalforinsteine. Eine besonders
F)rmgebung, die mehrfach angetroffen wind, ist
lie Ve -engung der Auslaufzone des Drelic.fens ; dies
(Wart z t teil .veisen Ktahlung des Klinkers in, Olen
und zu; schnellen Abnutzung des Ofenfutters ,n die-
sem At schnitt_
Sowohl praktische Erfahrungen als auch theorctische
Cfherlegungen ftihren zur Erkenntnis, dad der Dreh-
ofen ohne Einschniirungen bz-w. Erweiterungen die
derzeit g , instigste Ofenform darstellt. Die Dreiirohre
der mr dernen WarrnetauscherOfen weisea hereits
durchwe.gs einheitliche Querschnitte auf. Schtechte
Erfahrungen mit Drehofen verschiedener Quer-
schnitte veranla3ten die Zementindustrie der Sowjet-
union, rur noch Olen mit einheitlichem Durchmesser
zu bauen,.
19.1.1. Of.mfdlIungcgraci
Die Ma:erialftilleng ina Drehofen bildet einen Kreis-
abschni t des Ofnquerschnittes. Das Flachenv rhalt-
nis diesel Kreisabschnittes zum gesainten Ofenquer-
schnitt 'a Prozent ausgedriickt wird als OfehfUllungs-
grad f bezeichnet (siehe Fig. 193.).
Ofenfrillungsgrade schwanken in den Grenze i von
etwa 5 UnebbAngig vora Ofenclurchnies er ist
der Fulliulgsgrail hit- die verschiedenen Wertz des
Zentriwinkels rc wie
Zentrk\a inkel
Centric angle cc
11C '
105 '
100 '
95'
90'
BO'
75'
70'
Der Einflu3 des Dfenhillungsgrades auf den Derch-
satz des Drehofen; ist in Fig. 19.4. dargestellt. Drei
Kurven reprasentieren FCillungsgrzele von 7, 1' und
13 Vo, wit den dazugeharigen Durchsatzen in t, h (dr
Drehofen rift Durchmessern von 2 his 3.5 m.
19.1.2_ 0'?;ineigun;
Es gibt k eitie allgemein giiitige Regal fur (lie richtige
Neigung von Dreil5fen. Neigungen von Drehofen lie-
384
Zq
19. The rotary kiln
highly labor consuming, job, requiring specially
shaped refractory bricks. A kiln shell shaping which
is particularly disadvantageous, Is the narrowing of
the kiln's discharge end; this results in partial cooling
of the clinker in the kiln and in a rapid wear of the
refractory in this section. I
Practical experience as well as theoretical delibera-
tions lead to the observation that rotary kilns without
constrictions or enlargements represent currently the
most useful kiln construction. The ;hells of modern
preheater kilns already sh'c)w uniformity throughout
the cross-sections. Unfavorable experience with
rotary kilns of different cross-sections, prompted the
cement industry of the SOviet Unio). to build rotary
kilns with an invariable diameter exclusively.
19.1.1. Degree of kiln
The feed forms a segment of the rotary 1- iln's cross-
: ection. The area ratio of this segment to the area of
the kiln's cross-section expressed in percent is
called the kiln's degree or percent of filling f, (see Fig.
19.3.).
Fig 19.3. Scheinatische Darstellung des OfenInflungsgra-
des
Fig 19.3. g
Schematic of the de ree of kiln filling
Kiln filling degrees fluctuate within the limits of
about 5-17 go. Independent from Ulf- kiln's diameter,
the percent of filling for the different values of the
centric angle a is as follows;
r -tfenfrillungsgrad 0/0
010 of kiln filling
15.65 o/o
13.75 (lib
12.10 0/0
10.70 0/0
9.09 0/0
7.75 0/o
6.52 oio
5.40 0/0
4.50 nio
Tile influence of the degree (.1 filling to the rotary
kiln's capacity is shown in Fig. 19.1. Three curves
represent filling degrees of 7, 10, and 13 0/o, with the
corresponding capacities in t/h for rotary kilns with
di imeter from 2 to 3.5 m.
/P./.2. Kiln slope
No generally valid rule exists for the proper slope of
rotary kilns. Rotary kilns shpv slopes from 2 to 6 0/o.
 .1
19.1. Ausfri nrungsformen uas Drehofens 19.1. Types of rotary kAns

Fig 19.4. OfeuRillung.tgrail end Drehofendurchsatz

11'6 -
1 0" Fig. 19 4. Degree of filling versus rotary kiln capacity

10'0'

.7.
Ins ide kiln dia me ter

10 20 30 35 lin
Drenolendurchsotx

60 120 1150 210 Win

Rotary kiln capacil y

gen zwi ir- hea 2 und 6 Vo. Meistens triff:, man jr loch
Ofen mit Neigungen von etwa 2-4 Wo znr Hod? )rita-
ln an. Eirsprunglich hatten Drehofen qn56ere 1fei-
g , ingen lei niedrigen Umdrehungszahlon von -,tv a
05-0.75 LUrnin. Geringere OfennuiguLrg erk dert
e i ne ho'wre Drehzahl ; dies hat den Vo;teil, dad das
Ofenmaterial besser gemischt und eLrem intensi-
veren Warmeaustausch ausgesetzt wird. Nlan
erreicht auch mit geringerer Neigung hohere )(en-
hillungs grade. Aus praktischer Erfahrung resuliert,
daft den folgenden Ofenneigungen im prakti; :hen
Ofenbetri!b optimal erreichhare Ofenhillungs; rade
entsprechen; siehe Tabelle 19.1.
Most kiln slopes are between 2 and 4 olo to the hori-
zontal. Originally, rotary kilns had higher slopes with
lower revolutions ranging (rola 0.5 to 0.75 rpm. Lower
kiln slopes require higher numbers of revolutions;
this has the benefit of better mixing of the kiln feed,
together with a more intensive heat exchange. Lower
slopes also permit higher degrees of kiln filling or of
kiln load. Practical experie'r, :e resulting from kiln
operation shows that the following kiln slopes yield
the corresponding average kiln loads; see table 19.1.

Tabelle 19.1. Table 19.1.

Drehoienneigung and Ofenifinungsvad

Rotary kiln slope ver as .11n load

Ofenneigung No Entsprechender Ofentullungsgrail an

Kiln slope No Corresponding kiln load 0/

4.5 ',la 9 a/o

4.0 0/o 10 0/s
3.5 No II Vo
3.0 wo 12 No
2.5 No 13 0/

:kndererseits wird behauptet, dab der Clenfrillv ngs-
grad vorn Verhaltnis der Lange (L) zum 1,?nrc:hrn sser
(D) des ()fens abhangt. NaBdrehofen mit 'einem './D-
Verhaltr is von 40 und darriber weisen Fullungstrade
his zu 11 0/o auf [1761 dedenfalls bestim nt die lei-
gong des Drehofens in erster Linie den ngs-
g[ad, wobei ein steigendes L/D-Verhaltnis den Fril-
lungsg -ad noch erhohen kann.
fm praktischen Ofenbetrieb soil ein Frillungsgrar' von
1:1 A) nicht uberschritten werden, da 1rohere ['CIL
tungsgrade den Warmelibergang versddr chtern.
On the other hand, it is said that the kiln load
depends on the length (L) to diameter (D) ratio of the
kiln. Wet process rotary kilns with an LID-ratio of 40
and more, show kiln loads of tip to 17 % 0761. In any
case it is the rotary kiln's slo'pe which determines the
kiln's load in the first place; in addition to this Is an
increasing L/D - ratio a factor, v-hich can contribute to
the kiln's higher load!
In practical kiln operation the kiln load should not
exceed 13 ,/o, since higher kiln loads impair the heat
transfer.

385
 3l

EN')lac ation of Kiln, Cooler Operation by Mr. Kimura

No.4 : Modification plaA during Kiln stoppage
on 22 Dec. '97 at 14:45 16 :30

1. Status of this meeting

cooler was stopped on 21 Dec. at 20:00 by falling down of 2 pieces of nose

ring of kiln discharge end.
0 In this meeting, proposal of next cooler narrowing and necessary modification plans
were explained to CHC.

2. New narrowing idea of cooler

Tis narrowin4 plan comes from much experiences of ONODA.

3. Installation of kiln burning zone pyro meter ( 24T72 ) at the side of kiln firing hood

4. New installation of 2 inspection holes at cooler

5. Relocation of grate plate thermometers to check the clinker bed conditions properly.

6. Guide vanes for cooler 1st chamber cooling air duct

These modification items are officially proposed by UBE's letter. ( Ref. No. A/N-234
dated 2.4 Dec.'97 )
 32
Explanation of Kiln, Cooler Operation by Mr. KitniAVok
16 Dec. And No.5:SumaryfInstciom
Instruction for Next Kiln, Cooler Operation
on 25 Dee. '97 at 14: 00 16 - 30

1. Status cf this meeting

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.

2. Page 4/12 of the report " Trend after action '

(.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

4/12 of the report.

Kiln
torque

70

19 Dec. I )ate and time

16 : 50
 33

Free
CaO

19 Dec. Date and time

16 : 50

3. Kiln material filling ratio

S = 1.667 x T x M. x R = 7.2 %
AxLN9
T = Kiln passage time ( 28 min. )
M = Clinker production 3900/24 = 162.5 t/h
R = Average material in On
R + 1.0 - 1. 055

R 1 = Material at kiln inlet

R j = 1 55 t/t x (1- 14)c ) 1- 1.0 t/t cl' x c 1.11 (q) c = Decarbonation ratio = 80% )
100 100
A = Kiln cross section area = 7" x ( 4.55 - 0.4) 2 = 13.52 m2
4
L = Kiln. length = 76m
G = Average bulk density = 0.9 + 1.27 = 1.085 Um'
2
In case of the calculation at the most recomn endable kiln passage time : T = 28 min the
filling ratio S = 7.2 %.
In case of the passage time T ( before the kiln burner shape adjustment )

S= 7,2 x 21 = 5.4 %. ( lt is too low. )

28
The target value of kiln passage time should be 28 min. 30 min.
After fie action for the kiln burner long flame on 19 Dec.'97, the passage time is about
32 min ( 13y the time difference of trend chart of kiln inlet temperature and burning
zone to trip.
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 35

4. Kiln heat load, Coating length and kiln inlet hood temperature

Kiln heat load Coating length Temperature of kiln

( kcal/ in2 h) ( m ) inlet hood ( C )
4.2x 106 17 18 .950

5.0 x 10 6 22 1050

5.5 x 106 25 1150

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(,

1 S ki,Qr 4.4 Imo/

-
iS
inKe t h000t iS qs-O c
(/.50 G, Coal ir9 occuir'S
12 1- 0 /4C ckoo( MC o(utrt. iC OnRif tAiS cU-e4.

Around 4.2 4.7 x 10 6 kcal/m2 h is a recommendable range of kiln heat load for CHC
kiln.

5. Kiln bi.irning 'zone temperature and kiln power

( Page 4/6 of the report " Report concerning daliaged grate plates" )

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.

7. Kiln torque vs kiln burning zone temperature.

( 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.

8. Red river in case of too long burning time

Red river occur at the following 2 cases

- Too high temperature of kiln burning zone ( it is the case of CHC )
- Too long burning time
 37

Temp.

1450C

1250C

KjIii length (m)

The largeo(eause smaller A lite size ( large size clinker) :
The smallo(cause larger A lite size ( Dusty clinker ) then, red river easily occurs. ( But,
this case of red river is not CI-IC case. ) ; 4. 2

9. Countermeasure for the damage of castable at SC ( Swirl calciner) of RSP

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
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