Mod 3-Process Engineering Objectives

Process Engineering
Training Program
MODULE 3
Process Engineering Objectives
Section Content
1 Kiln Output Target
2 Output Targets, Performance Benchmarking
3 Technical Job Objectives
4 Generic Job Profile
5 BCC North America Process Engineering Training Program.
HBM Process Engineering Conference

Roberta Kiln Bottlenecks
Benchmarking Kilns- The New Target
Presentations
Benchmarking- Colin Paxton
Process Engineers Conference
Output targets and Benchmarking
Blue Circle Cement
PROCESS
ENGINEERING
TRAINING PROGRAM
MODULE 3
Section 1
Kiln Output Target

(lecture 20)
KILN OUPUT TARGETS
CONTENTS
1. INTRODUCTION
2. DEFINITION OF OUTPUT
3. METHODS USED TO ESTABLISH TARGET OUPTUTS
3.1 Wet and Semi Wet Process

3.2 Long Dry Porcess
3.3 Suspension Peheater Process
3.4 Precalciner Process
3.5 Semi Dry Process
APPENDIX 1 Notes on Hearth Velocity Calculations

- Preheater and Precalciner Kilns -
KILN OUTPUT TARGETS
1. INTRODUCTION
The objective of this paper is to establish a method of determining a target output for
a given kiln system. The target will be based on the basic kiln tube dimensions and, in
the case of the semi-dry system, the grate preheater.
The reasons why kiln tube and, in one case, preheater size has been selected as key
bottleneck is the cost of modification. Only on very rare occasions has a kiln tube been
enlarged in diameter or length to increase kiln output and this would normally be a very
high cost project. The same is true of the Lepol grate. It will also be clear from the
targets that on very few plants is the kiln size the ultimate bottleneck and that too
frequently the size of auxiliary plant and/or failure to apply best operating practice are
the prime reasons for failing to achieve target output.
The targets will be quantified by evaluating the segregating kilns of similar process type
and selecting the best output performance for each category.
There are two principal reasons for establishing a kiln output target:
- For existing kilns, to quantify the benefits which can be

achieved if the system bottlenecks which restrict kiln
output can be removed.
- For new plants, to enable the sizing of ancillary equipment,

such as raw and cement mills, to be accurately assessed.
In both cases the overall objective is to maximise available plant output for a given
financial investment.
1
2. DEFINITION OF OUTPUT
There are many means of defining the term clinker output from a given plant and a
different figure will result from each method.
Some examples of output definition are:
I) Annual average )
ii) Best month ) In all cases as T/24H
iii) Best week ) of kiln operation
iv) Best day ) Note: References to t/d have
V) Guaranteed ) the same meaning as T/24H
vi) Specified )
Of the above
I) to iv) are at least related to actual plant performance.
V) is often the figure quoted by the plant supplier from new. The guarantee output is
usually measured over l-3 days and may not even have been achieved in practice. As
such little reliance can be placed on this figure to evaluate plant performance.
vi) is frequently a “comfortable” figure selected by the operating company and will
again bear only a limited relationship to actual plant operation and will not be used in
this paper.
All the output figures 1)-IV) can be used for different purposes, i.e. the provision of raw
milling capacity should be related to the best week kiln output as storage of raw meal/
slurry will be limited and the supply of raw meal/slurry must at least be able to keep
pace with the kiln demand during a best week.
The ratio of best day/week/month to annual average will be different for each plant and
can be used as a means to quantity kiln operating stability. A typical example from a
wet process plant is shown in Figure 1. Although useful parameters, best day and week
production rates may often be unreliable as performance indicators due to calibration
of kiln weigh feed systems etc. For this reason best monthly figures will be used to
define kiln output targets. The expected ratio to convert best figures to annual average
are similar to those of Masons, i.e:-
Annual average (t/24h) = Best month (t/24h) x 0.97

Annual average (t/24h) = Best week (t/24h) x 0.94
Annual average (t/24h) = Best day (t/24h) x 0.91
Finally, where guarantee figures are relevant
Annual average (t/24h) = Guarantee (t/24h) x 0.93
2
. SamMasons Kiln-1
Daily production on days when kiln ran 24 hr. (OPC only)
50
40 -
g 30
z
75
g 20
10
0
921-940 9 6 I-980 1001-1020 1041-1060 1081-1100 1121-1140 1161-1180
9 4 I-960 981-1000 1021-1040 1061-1080 1101-1120 1141-1160
Tonnes / day
t/d Factor to
Annual average
1148 07932
1123 0.953
w 1105 0.968
Annual Averaae 1070
3. METHODS USED TO ESTABLISH TARGET OUTPUTS
In the past many methods have been employed to target kiln outputs. The majority of
these have used kiln internal volume as the principal parameter, but volume as such has
not proved to be an adequate measure as it bears little relation to the phenomena which
actually cause a limit to kiln output.
It can be generally stated that two factors tend to restrict ultimate kiln production.
- A limit to the amount of heat which can be transferred within the kiln
tube. This will be related to the surface area within the kiln.
- A limit on the maximum gas velocity within certain areas of the kiln
system. Beyond this limit the quantity of dust generated, either internal
or external to the kiln system, will cause a limit to the kiln output.
In the following sections the effects of heat transfer and gas velocity limits will be
examined for each type of kiln process. From this examination the limits will be
quantified and a target output given for each kiln system.
It is important to note that general observation of kiln behaviour during recent years
has led to a conclusion that only in a few special cases have kiln outputs been restricted
by heat transfer and that gas velocity limits are the single most important bottleneck.
This will diminish the importance of the previous BCI targets based on heat transfer and
set many new targets for BCI kilns.
3.1 Wet and Semi-Wet Process
3.1.1. Assessment of Performance
Previous assessments of wet kiln performance concluded that both heat transfer and gas
velocity played an important part in limiting kiln output. Although there may be a link
between internal surface area and wet/semi-wet kiln output this is indirect. The
indirect link is best ‘expressed as:
- Insufficient heat transfer area is available in the burning and

decarbonation zones
- Results in high gas temperature entering the chain zone
- Results in rapid drying of slurry in the chains
- Causing a longer zone of nodule destruction within the chain

system
4
and
-0 More dust being generated within the chains
Although this link may result in high dust generation, evidence from the diminishing
number of wet and semi-wet kilns in operation is that dust will inevitably be generated
from dry material in the chain system and that kiln back end cross-sectional area is the
main limiting factor to wet and semi-wet kiln output. Previous attempts to use a gas
velocity to express this limit would have predicted much higher outputs for low moisture
feed and semi-wet process chained kilns than have been achieved. It appears that as
feed moisture is reduced, drying becomes more rapid and thus the amount of dust
generated would be increased even at the same gas velocity. Ultimately, this is
confirmed by long dry process kilns where even lower chain gas velocities can be
tolerated.
In practice, then, this assessment of wet/semi-wet kiln output is based purely on kiln
cross-sectional area considerations. As the majority of wet/semi-wet kiln dust is
generated within the chain zone, back-end cross-sectional area is taken as
representative and a deduction of 0.4 m from kiln inside shell is allowed for chain
hangers/brick lining of the chain zone etc.
Table 1 lists a number of wet/semi-wet kiln performances both within BCI and other
European cement plants. Some data from closed works is also included as this historical
production information remains valid despite plant closure.
From this data it can be seen that the clear limit to wet kiln output is established by
the cross-sectional area parameter t/d/m2 and that heat transfer considerations are
very much secondary to this. Kiln gross dust loss will increase rapidly as the velocity
limit it approached and achieving target output will require best practice in chain
configuration, cooler efficiency, flame characteristics and dust return.
3.12. Target Setting
It is concluded that an optimised wet/semi-wet process chained kiln may achieve a

target rating of 110 t/d/m2 (c.s.a) This may include the requirement to install dust
scoops as dust return to the mid kiln region will be essential when gross dust losses of
up to 50% are to be accepted. Conventional burning zone insufflation of this quantity
of dust will cause instability and difficulty in kiln control.
Table 1 contains the targets established for the wet and semi-wet process kilns.
5
TABLE1
WET KILN PERFUWQ
Works I Kiln No. K i l n Dlmanslons (m) Best Month Output t/d/m2 t/d/m2
Tayl;t tyd;“4 On
Diamatar b.e x b.z x 1 t/d Klln 1 Surface Area K i l n b.e x - s e c t i o n m
K i l n b.e. x - s e c t i o n
EC1 Northf laet 2 5.64 x 6.01 x 198.1 2325 0.697 107.8 2370
Northf leet 5.64 x 6.01 x 198.1 2080 0.623 96.5 2370
Northf leet ii 5.64 x 6.01 x 198.1 1798 0.539 83.4 2370
Masons 5 4.12 x 4.42 x 152.4 1190 0.645 109.5 1195
westbury 4.12 x 4.42 x 137.2 1070 0.649 98.4 1195
w&bury : 4.12 x 4.42 x 152.4 1170 0.640 107.6 1195
Shagamu 4.55 x 152.0 1350 0.681 99.8 1490
Shagamu : 4.55 x 152.0 1345 0.679 99.4 1490
Ewekoro 3 4.12 x 4.42 x 152.4 037 0.458 77.0 1195
Athl River 3.15 K 2.85 x 3.15 x 100 650
Athl R i v e r : 3.45 x 112.0 805
Ravena 6.1 x 5.33 x 5.64 x 177 2374 0.807 93.0 2805
Ravena : 6.1 x 5.33 x 5.64 x 177 2461 0.837 96.4 2805
CETIC Lumbras 4 3.7 x 3.6 x 116 650 0.547 76.0 940

Lumbres 5.5 x 4.75 x 160 1465 0.633 71.7 2245
Obrg i 7.0 x 6.25 x 202 2655 0.686 77.6 3765
Ohrg 10 7.16 x 6.33 x 227 2600 0.587 72.4 3950
Llxhe D 5.80 x 5.3 x 185 1890 0.642 02.5 2520
Bar1 In 3.75 x 3.45 x 140 705 0.509 60.0 970
Barlln 65 3.75 x 3.45 x 140 510 0.368 57.9 970
Cant1 n 1 3.60 x 3.00 x 130 675 0.591 83.9 885
OTHERS Greencastle 5.79 x 5.18 x 5.64 x 176.8 2090 0.733 91.6 2510
Dal Valle :, 4.27 x 3.81 x 137 1030 0.672 07.6 1295
Portland 3 5.03 x 4.27 x 152 1480 0.752 07.9 1850
Serrima 5 4.64 x 171 1430 0.628 101.3 1555
CLOSED M)RKS Norman 1 2.38 x 2.75 x 91.4 MQ. 0.571 110.4

Toltaca 3‘05 x 3.5 x 107.8 99.7
Trident : 3.66 x 137 iii XZ 107.8
3.2 Long Dry Process
3.2.1 Assessment of Performance
The kiln systems examined in this section are defined as those kilns which have a dry
raw meal feed to a kiln equipped with a chain system. In addition a cruciform may be
present for heat exchange purposes. A one stage preheater addition is also included in
this section as these kilns will normally have a chain system and will be limited by the
dust loss generated in the chain system as opposed to the hearth velocity limit of multi-
stage preheater kiln systems.
As with wet process kilns the main limit to long dry process kiln performance is
assessed to be dust loss. As production levels are increased dust loss from the kiln
increases to a level at which operating stability is reduced and excessive quantities of
dust overload the collection and handling systems.
Tables 2 and 3 list a range of operating long dry and one stage preheater kiln
performances both within BCI and other operating groups. As with wet process kilns
some data from relevant but now closed plants is also included.
3.2.2. Target Setting
The target performance for a long dry kiln has been achieved at several plants and is
set at 93 t/d/m2 of kiln back-end cross-sectional area. Dust return on these kilns is
conventionally direct to the kiln back-end. Long dry kiln targets are given in Table 2.
As the assumption is held that one stage preheater kilns are also limited by gas velocity
in the kiln back-end/chain section, the expected additional output from this system will
be in proportion to the decreased fuel consumption of the one stage against long dry kiln
system. The standard fuel consumption for a one stage preheater kiln is 930 kcal/kg and
for a long dry kiln 1000 kcal/kg. With allowance for carbon dioxide from decarbonation
in both cases this would indicate that gas velocity in the chain system for a one stage
preheater kiln is 7% lower than for a long dry kiln. This confirms the target of 100
t/d/m2 which would be expected from analysis of one stage preheater kiln performance
in Table 3.
3.3 Suspension Preheater Process
Suspension preheater kiln systems are defined as those systems which have between 2
and 6 stages of preheater cyclones and up to 25% of auxiliary firing to the preheater.
Previous assessments have used a combination of kiln gas velocity and kiln internal
surface area to determine the potential output from suspension preheater kilns.
Observation of behaviour of these kilns has tended to indicate that back-end hearth
velocity is the absolute limit to preheater kiln production and that this measure is the
most accurate means of assessing preheater kiln performance.
7
TABLE2
LONG DRY KILN PERF-
Works & Kiln No.
3.75 x 3.45 x 125

4.27 x 3.66 x 127.9
4.27 x 3.66 x 127.9
4.27 x 3.66 x 127.9
4.27 x 3.66 x 127.9
4.27 x 3.66 x 127.9
4.27 x 3.66 x 127.9
CETlC Horlsel Ice 3 4.2 x 3.5 x 156.3 1075 0.657 94.8 1054
Razrato 1 4.8 x 4.0 x 165.0 1185 0.591 77.9 1415
OTHERS Saud1 Cement I-4 5.0 x 170 1548 0.630 93.2 1545
Regina 3.35 x 114.3 610 0.580 89.2 636
Hofuf l-2 3.2 x 90.0 344 0.430 55.9 572
Hofuf 3 4.0 x 130.0 790 0.540 77.6 948
Hofuf 4-5 5.0 x 170.0 1474 0.600 88.7 1545
RIVW 5.33 x 4.89 x 170.7 1709 0.687 89.5 1775
VlCtOfVill8 5.33 x 4.89 x 174.0 1678 0.662 87.9 1775
Joppa 5.0 x 4.4 x 168.0 1637 0 . 7 3 8 9 8 . 5 1545
Hag&&.own : 5.18 x 4.57 x 158.5 1686 0 . 7 7 4 93.9 1669
Speed 4.57 x 152.4 0.500 73.0 1271
Union Bridge : 3.51 x 121.9 tz 0.570 89.6 706
MOflt4W"P43~ 3.5 x 121.0 615 0.520 81.5 702
BrookfIeld 3.7 x 3.4 x 134.0 650 0.500 76.0 795
CnSStmom 4.55 x 3.81 x 162.0 1197 0.640 88.5 1256
TABLE3
* BEFORE CONVERSION TO 2 STAGE PREHEATERS

Table 4 lists the existing performance of suspension preheater kilns, both from within
BCI and from other cement producers. In order to determine hearth area in cases where
this is unknown, a factor has been developed to relate hearth inside refractory area to
kiln inside shell area based on normal design parameters. Gas volume at the kiln back-
end has been calculated using known or estimated levels of auxiliary firing and known
or estimated levels of raw meal decarbonation entering the kiln. These assumptions are
contained in Appendix 1. From this hearth velocity has been derived using a standard
1150°C as kiln back end temperature. Table 4 shows the results.
No account of preheater sizing has been used in the current assessments as the advent
of larger inlet size cyclones in preheaters has enabled low cost uprating of preheaters.
3.3.2. Target Setting
From the data contained in Table 4 it can be seen that a hearth velocity of 34 m/s is
the maximum which can be sustained without an excessive pick-up of raw meal from the
kiln back end hearth area. This velocity limit has been applied to BCI preheater kilns
to produce the targets shown in the table.
3.4 Precalciner Process
Precalciner kilns are conventionally divided into two groups - Air Through and Air
Separate. For the purposes of assessments these groups will be examined separately.
3.4.1. Air Through Precalciners
AT System Limit
For the purposes of this section Air Through precalciner kilns are assumed to be systems
in which greater than 20% of the fuel is fired in the precalciner/preheater and where
no tertiary air duct is present.
A summary of performances is given in Table 5. Blue Circle no longer operates any Air
Through precalciner kilns and as such our knowledge of the actual kiln outputs is
limited. Previous work on this design of kiln system concentrated on heat transfer
surface area as being most critical to kiln production. However, evaluation of kiln
hearth velocities reveals that many of the Air Through kilns are operating close to the
limit which prevails for preheater kilns. With such evidence the surface area limit
currently used has been removed until further data on heat transfer limits has been
acquired and in common with preheater kilns the hearth velocity has been taken as the
current limit to output.
Target Setting
From the data contained in Table 5 it can be seen that the hearth velocity limit of
34m/sec has been used to establish the targets for Air Through precalciner kilns.
10
TABLE4
SUSPEUSION PREENER KILN PERFoRMME
Works & Kiln No. Kiln Dimensions (m)

Diameter b.e x b.z x
OTHERS Golden Bay 6 3.81 x 4.11 x 60.6 4 2.18 182.2 47.4 1195
8errima 6 5.0 x 85 2.17 -156.4 29.1 3040
Llchtenburg 4 3.75 x 53.7 t 2E 1.52 97.3 27.8 1050
Llchtenburg 5 4.80 x 68.0 2.18 134.8 31.7 2200
8oucau 3.9 x 3.8 x 60 t 835 1.29 86.8 23.0 1235
l Acutal velocity at 1150 C

TABLE5
AIR TtlROUW PRECALCINER KIIN RATImS
Works & Kiln No. Hearth Velocity
El Alto
Setubal
Pedro Leopold0
zapot11t1c
Castlllejo de Anover
tkeerlda
Limerick
Guangzhou
Pioneer
Rio Bljao
La Coum-me 32.85 3105
Beocln PREWL-AT 4.0 x 60 3000 3.62 197 29.29 2484
Han11 PREPCIL-AT 4.8 x 60 3000 3.62 197 29.28
Allen PREPDL-AT 4.0 x 65 2200 2.99 216 36.21 Hi2
Darlca PREFOL-AT 4.6 x 70 3000 3.25 216 32.85 3105
ssang Yong-Seoul PREPDL-AT 5.2 x 70 4200 3.90 232 33.29 4290
Partlran PREPCIL-AT 4.6 x 70 3200 3.46 231 35.04 3105
Sllt8 PREPOL-AT 5.2 x BO 4700 3.90 260 37.25 4290
Tabllgbo
Dodam PREPDL-AT
PREFQL-AT 4.8
4.0 x 85
60 2400
3000 2.04
3.62 158
197 29.28
23.42 %?3
Luoq PREFDL-AT 4.8 x 60 3000 3.62 197 29.28 3484
Reclfe PREPDL-AT 4.0 x 60 1500 2.21 147 24.69 2066
Palmelras de Golas PREFOL-AT 3.6 x 54 BOO 1.47 100 18.71 1454
Monay PREPOL-AT 4.2 x 65 lBO0 2.32 159 25.54 2396
Sang Yang-Donghae
Souselas PREPDL-AT 5.0
5.2 x 70~
75 4200
3500 3.23
3.98 232
211 33.29
30.68 zx
Loma Negra-Catamarca PREPOL-AT 4.4 x 70 1600 1.82 127 19.83 2743
Balcwmr PREPDL-AT 4.6 x 74 2500 2.56 181 27.37 3105
Cantagalo PREPDL-AT 4.0 x 60 1500 2.21 147 24.69 2066
Orlraba PREFOL-AT 4.4 x 65 2400 2.94 191 29.75 2743
Llchtenburg No.6 (Phase 1 ) PREFOL-AT 4.2 x 63 1300 1.73 115 18.45 2396
Pedro Leopold0 PREPDL-AT 4.4 x 65 2200 2.69 175 27.27 2743
Per kasa PREPDL-AT 5.4 x 78 4750 242 34.24 4717
Jura-Wlldegg PREPDL-AT 3.8 x 56 1800 3:: 198 34.94 1752
Safl PREPDL-AT 4.2 x 60 1600 2.23 141 22.70 2396
3.4.2. Air Separate Precalciners
Assessment of Performance
Air Separate precalciners are naturally assumed to be those which have a tertiary air
duct. The fuel fired into the precalciner system is normally between 50 and 60% of the
total fuel but there may be cases where this assumption is erroneous as precalciner
design was inadequate to sustain high firing levels.
Table 6 lists the AS precalciner kilns within BCI and, where reliable data is available,
from other plants.
As with AT systems much investigation has been previously centred on the kiln internal
volume ratings of the manufacturers and the BCI internal surface area limit for heat
transfer. With current information there is only slender evidence that heat transfer in
the kiln is a limit to production and this is confirmed by the ability of KI-ID to introduce
the Pyrorapid kiln with length to diameter ratio of 10-12:1 rather than the conventional
16:l. This would be expected to yield a lower output for a given diameter of kiln but
there is, as yet, little sign that this is the case. This may be due to the ability of the
riser/calciner/lowest cyclone stage to compensate for failings in the kiln heat transfer
and produce, overall, a satisfactory thermal profile. This moves the bottleneck to the
hearth area as with the other preheater/precalciner processes. Calculations have been
completed on the known data and the results given in Table 6.
Target Setting
As a result of the analysis above, a target hearth velocity of 30 m/s has been assigned
to Air Separate precalciner kilns and the target outputs are given in the table.
3.5 Semi Drv Process
The kiln systems examined in this section all have a grate preheater, almost exclusively
manufactured by Polysius. This process is most sensitive to raw material
characteristics, specifically the friability of the nodules. Friability is measured as a
percentage breakdown of nodules due to abrasion and mild impact forces and has a
’ higher figure when nodule characteristics are worst. A typical range would be 0-13%.
Breakdown of nodules on the Lepol grate and within the kiln generates dust and will
reduce the permeability of the nodule bed. Gas flow will be reduced and kiln output
restricted.
13
TABLE
6
AIR SEPARATE PRECALCINER KILN RATINGS
Works & Kiln No. K Type Kiln Dimensions (m) Best Month Output TPD/ti TPD/ti Hearth Velocity Target based on
Diameter x length TPD Kiln Internal Kiln Area b.e m/s 3Om/s
Surface Area x-section @ hearth tpd
Rawang No.3 NSF 4.7 x 74 5070 5.07 349 29.26 5200

Kedah No.1 NSF 4.7 x 74 5000 5.00 344 28.85 5200
Cauldon ILC 3.95 x 58 3110 4.81 314 29.76 3135
Kanthan No.3 PYROCLON 4.2 x 57 3350 4.92 296 26.56 3785
Melon No.9 ILC 3.6 x 49 1900 3.86 236 24.84 2295
Dunbar PREPOL 4.35 x 3.92 x 6 0 3190 4.73 260 22.83 4190
Aalborg-Rordal SLC-s 4.75 x 74 5500 5.44 370 30.85 5356
Tonasa-Sulawesi SLC-s 5.55 x 87 7500 5.38 367 28.87 7795
Hoang Thach SLC-s 4.15 x 64 3300 4.38 299 27.12 3650
Siam-Tabkwang-No.5 SLC 6.0 x 96 9000 5.33 366 28.06 9625
Siam-Khao Hong SLC 6.0 x 106 10000 5.36 406 31.17 9685
Gujarat SLC 4.75 x 75 6000 5.85 404 33.65 5350
Siam-Tabfa 2 SLC 5.0 x 80 5500 4.76 331 26.94 6125
Adelaide Brighton SLC 4.57 x 67 4150 4.73 304 25.85 4815
Sikka SLC 3.75 x 75 2300 2.91 261 26.08 2645
Ibuki NSF 3.8 x.79 3045 3.61 336 33.03 2765
Tochigi NSF 3.5 x 66 2640 4.11 350 38.27 2070
Akoh No.2 %F 5.6 x 94 7600 4.95 E 27.98 8150
Chichibu No.1 3.9 x 54.8 2400 3.98 23.91 3010
Hachincde SCS 4.7 x 75 4500 4.44 310 25.97 5200
Akoh No.1 SCS 4.7 x 81 5000 4.57 344 28.85 5200
Gifu KSV 4.1 x 60 2724~ 3.91 253 23.22 3520
Isa KSV 6.2 x 105 9900 5.17 375 28.56 10400
Saitama DD 5.0 x 83.1 5500 t:-E 331 26.94 6125
Kawara MFC 5.4 x 95 7200 367 29.00 7450
Rai lton PYRCCLON 4.0 x 58 3000 4.57 295 27.59 3260
Sangwon PYROCLON 4.8 x 52 3300 4.59 217 18.00 5500
Ruderdorf No.5 PYROCLON 5.2 x 61 5000 5.44 276 22.15 6775
Perlis PYROCLON 4.0 x 56 2700 4.26 265 24.83 3260
Spenner PYRCCLON 4.08 x 40 2136 4.62 201 18.45 3475~
Grasim PREPOL 4.4 x 65 3300 4.04 263 22.86 4330
%rone PREPDL 4.0 x 54 2510 4.11 247 23.08 3260
Danyang PREPOL-CC 5.2 x 78 6000 5.10 332 26.57 6775
Tong Yang PREF'OL-CC 5.6 x 87 7200 5.07 339 26.51 8150
TPI Saraburi PREPOL-CC 5.6x87 7500 5.28 353 27.62 8150
Lexos CLE-RSP 3.6 x 69.75 2400 3.42 299 31.37 2295
Advice received from Polysius is that kiln size is not the prime determinant of the
semi-dry process potential output and that grate preheater size is the important
feature. Polysius ratings are 14.5 t/d/m2 grate area. As there is no immediate
correlation between the Polysius definition of very poor to good friability and
inadequate friability data is available for the majority of kilns in Table 7 a target for
best materials has been used.
3.52. Target Setting
From the data available in Table 7, a target of 14.5 t/d/m2 of grate surface area has
been selected. Resultant target figures are shown in the same table.
15
TABLE7
SEMI-DRY OIPOL) KILN f'ERFtHWWX
4.4 x 4.0 x 65
Vaslllko : 4.0 x 60 3.9 x 29.0 1593 2.35 156.6 14.09 1640
Vaslllko 4.0 x 60 3.9 x 29.0 1436 2.12 141.1 12.76 1640
Vlllaluenga 4.4 x 4.0 x 65 3.9 x 27.0 1531 2.01 121.8 14.54 1527
Vlllaluenga : 4.4 x 4.0 x 65 3.9 x 30.3 1600 2.11 127.9 13.61 1713
q
APPENDIX 1
NOTES ON HEARTH VELOCITY CALCULATIONS
- PREHEATER AND PRECALCINER KILNS
1. Hearth Area
Measurements of hearth cross sectional area have have been taken at several works.
From this information a curve fit of kiln internal shell diameter to hearth area has been
completed and is shown in Figure 2. This figure allows us to calculate hearth area form
a given kiln shell diameter with a reasonable degree of accuracy taking into account
differing refractory practice in the hearth area.
2. Gas Volume
A simple spreadsheet has been developed from which gas volume at the hearth can be
calculated. Base assumptions are (expect where precise data is available).
Suspension Preheater
i) Fuel consumption 820 kcal/kg
ii) Back end firing 10% on < 5m diameter kilns

20% on > 5m diameter kilns
iii) Feed to kiln decarbonation rate
30% at 0% back end firing

iv) Oxygen % at back end
1.3% at 0% back end firing

A T Precalciner
1) Fuel consumption 820 kcal/kg

ii) Precalciner firing 35% of total fuel
iii) Feed to kiln decarbonation rate 70%
iv) Oxygen % at back end 7%
v) Polysius AT kilns have + 10% hearth area due to-twin slope arrangement.
17
A S Precalciner
i) Fuel consumption 820 kcal/kg

ii) Precalciner firing 60% of total fuel
iii) Feed to kiln decarbonation 85%
iv) Oxygen % at back end 3%
18
FIGURE 2
Hearth Area vs. Kiln Diameter1
3 4 5 6
Kiln Diameter (m)
- Y=(0.3038X^2)-1. 745
Blue Circle Cement
PROCESS
ENGINEERING
TRAINING PROGRAM
MODULE 3
Section 2
Output Targets, Performance Benchmarking

PAPER NO. 13
OUTPUT TARGETS. PERFORMANCE BENCHMARKING
CONTENTS
1. INTRODUCTION
1.1 Target Setting

1.2 Performance
2. OUTPUT TARGETS
2.1 Kiln Tube

2.2 Ancillary Plant
3. PERFORMANCE BENCHMARKING
OUTPUT TARGETS. PERFORMANCE BENCHMARKING
1. INTRODUCTION
1.1 Target setting
Target setting in Blue Circle started through the practice of comparing the
performance of all kilns of a particular type with the best performing kilns both
within the group and worldwide. Targets were set based usually on the best day
performance of a particular kiln.
This data could then be used to direct performance improvement measures at

those units most likely to achieve significant benefits. This type of exercise also
highlighted those aspects of design and operation most likely to achieve high
levels of performance in new plants and could be used to influence new plant
design.
The following paper describes some of the specific parameters useful in target
setting on suspension preheater kilns and their ancillary plant.
1.2 Performance Benchmarks
The concept of a performance benchmark is an extension of a simple output

targeting idea into a larger area incorporating all of the important cost and
performance areas of cement manufacture. The paper on refractories (No.111
includes a short section comparing the refractory usage of suspension preheater
kilns. This data and the graphs and targets that arise from it are a good example
of a benchmarking exercise.
2 OUTPUT TARGETS
2.1 Kiln tube
2.1 .l Output target
The review of outputs of all suspension preheater kilns which formed the
background to the output target figures was made on the basis of tonnes/day per
m2 of kiln internal surface area. This data was originally based on the best days
performance of a particular kiln. Surface area has been the preferred basis
within Blue Circle because it was thought to represent more accurately the heat
transfer ability of the kiln. The accuracy of this approach may diminish with
large diameter kilns. With precalciner kilns in particular, it has been necessary
to introduce a scale of increasing output factors with increasing kiln diameter.
Others in the industry use factors relating to kiln volume which may
overestimate the effect of kiln size.
The surface area factor currently in use for suspension preheater kilns is 2.35
tonnes/day per m2 internal surface area. The surface area is based on the inside
shell diameter of the kiln (less 0.4m for refractory) and the length from the
cooler ports to the back end seal, less a 5m allowance for the clinker cooling
zone.
Experience with wet process kilns suggested that there was also a potential gas
velocity limit to kiln output. This was related to a position when dust loss from
the kiln reached an unacceptable level.
On a dry process kiln this limit is currently 175 tonnes/day per m2 kiln internal
cross section. In general the output calculated is above both the surface limit and
the velocity limit over the kiln hearth (see section 2.2.1), dry process kilns are
therefore normally regarded as surface area or hearth velocity limited.
For the Circle Cement preheater kiln at Manresa the surface area limit figure
represents a best day output potential of 1380 tonnes. The velocity limit figure
would be 1588 tonnes per day, the surface limit therefore applies.
2.1.2 Average and Annual Output Targets
It is clearly unlikely that a kiln will achieve its best day output on a continuous
basis. Some allowance must be made to correct for start up and kiln feed/speed
reductions during normal operation. This allowance for kilns with very stable
operating characteristics can be as low as 5% although this applies more for
precalciner kilns. The factor more usually applied is a 10% reduction from best
day output. This is expressed as a peak/average ratio of 0.9. This would give a
target average output of 1242 tonnes/day.
Finally when dealing with annual output it is necessary to consider the level of
annual running hours achievable by a kiln system. A very stable operation can
achieve up to 90% annual running hours (ie 7884 hours per year). It would be
more normal on a suspension preheater kiln to target 85% or 7446 hours. Other
manufacturers will make an allowance for planned stoppages and then target 90-
95% of the remaining “available” hours, the resulting tonnage targets are usually
very similar.
The above figures would give an annual output potential for the preheater kiln
at Manresa as follows:-
daily tonnes x No of days run

(1380 x 0.9) x (8760 x 0.85)/24 = approx 385,000 tonnes
2.2 Ancillarv Plant
2.2.1 Kiln inlet
The highest gas velocities in a preheater kiln usually occur at the point where
the gas flow crosses the kiln hearth and turn up the riser to the bottom stage
cyclone. The available cross section can be as low as 25% of the kiln cross
section. Kiln output can be limited due to raw meal recirculation if velocities at
this point approach or exceed 30m/sec.
2.2.2 Suspension Preheater
The preheater cyclones perform a heat transfer and a material separation

function. The limiting output of a cyclone will be related to its volume and
geometry. Overall a target related to the cross-sectional area of the cyclone
body (inside the refractory) has been found most useful. These figures are
generally based on 75185 tonnes/day per m2 of cross-section for new plant (75 for
lower stages 85 for top stage cyclones). Uprated plant can be pushed up to
93/l 16 tonnes/day per m2 but expect,very high preheater pressure drops at this
output (see 2.2.4). Also worth evaluating is the loading on the meal feed pipes
leading from the cyclones, figures above 10,000 tonnes/day per m2 of pipe cross
section should be avoided particularly if the feed material is known to be sticky
at higher temperatures.
2.2.3 Clinker cooler
The cooler paper gives indications of how clinker output targets can be related
to clinker cooler dimensions. In general terms the integral cooler design can
handle a wide range of outputs, the main indication of an output limit being the
acceptable level of clinker temperature. The maximum rating currently achieved
is 2.2 tpd/m2 related to surface areas of the cooler shells only. This related to
Manresa, gives an output rating of 1445 tpd.
2.2.4 Preheater pressure drop/fan capacity
Again this aspect of output limits has been discussed in the preheater paper. If
the kiln output potential is significantly above the original rating one can expect
increasingly higher preheater pressure drop as output is increased. Uprating of
the preheater fan is a common feature of modifications aimed at achieving kiln
target performance. Also of interest is the effect of increasing gas velocities
at the cyclone stages. If the output target indicates that cyclone inlet velocities
could approach or exceed 25 m/sec it would be usual to consider cyclone
modifications avoid excessive pressure drop. Velocities up to 30 m/sec can be
considered if cyclone modifications are expensive or impractical.
2.2.5 Other plant
Other plant to be considered in any review of output potential include:-
a) fans such as the precipitator fan

b) the gas cleaning plant
c) the raw milling plant
d) the fuel preparation and firing plant
3 PERFORMANCE BENCHMARKING
As indicated in the introduction, benchmarking represents an extension of the

targeting process to include other parameters important to the cement making
process. At this time benchmarking within Blue Circle group has progressed to
include the following 12 parameters.
1) Kiln output
i) Annual
i i ) Best month
2) Kiln fuel consumption
3) Clinker output per employee year
4) Kiln mean time between stops
5) Refractory consumption
6) Power consumption
i) Clinker
ii) Cement
7) Maintenance cost per tonne
8) Replacement capital spent per tonne
9) Development capital spent per tonne
10) Value of engineering stores stockholding
11) Lost time accidents per 1,000,000 hours worked
121 Working days lost per 1,000,000 hours worked
Table 1 shows the data on Manresa kiln No2 as used for the benchmarking
exercise and the comparative data is included as figures 13.1-13.18. It will be
noted that the kiln output levels are compared on the basis of best month
performance. The targets are based on the figures given in section 2 (ie the
original best day targets). This inconsistency does not affect the validity of the
comparative data but does make the average/peak ratio:-
(ie “annual average/best month” data in figure 13.31 significantly higher than
would be expected on a “annual average/best day” as discussed in section 2.
It will also be noted that there are a number of kilns reporting outputs above the
“peak” targets, this relates largely to the continuing application of process
improvements. Output targets on all kiln processes are currently under review
and it is forseen that future benchmarking exercises will take account of the
improved performance standards to be expected from kiln plant.
The use of benchmarking as a tool for generating improvements in other aspects
of works performance is perhaps not as clear cut as in output targeting. There
may be very good reasons why a particular plant has a below average
performance in a certain area. What benchmarking does achieve is a clear
comparison of performance and an incentive to study the areas where
performance is clearly below levels achievable elsewhere. It is not the intention
in this paper to go into all the above topics with respect to Manresa. It should
be noted however that many of the important parameters listed are discussed in
some detail throughout these course notes.
SUSPENSION PREHEATER PROCESS
Technical Benchmarks 1993
Kiln Output (% of Target)
Best Month
*0
(4
140
glls 1993
120 on 1 9 9 2
h9 1991
100
80
60
40
20
0
- BMB2 ABR6 BMBl ASH2 ASH1 PLM2 FIAKl LX34
GIN36 HRLl LTGS HOP1 HOP2 MNR2 RAK2
SUSPENSION PREHEATER KILN
TABLE 13.1
?m4EAlERA#xTss . m
I
16. Furl TV-
i) call - cd (Kcawg) 6610
- - 33117 I
39. thmbmr of Uorking Days Lost 922
39. Nmber of Lost T i m Pccxlents mer 1.000.000 l-h. Uorked 60 62.7
I M kw-tine Dam Lost cmv 1.000.000 H-0 Uartd 965

4
SUSPENS,ION PREHEATER PROCESS

Kiln Output (% of Target)
Annual Average
60
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GDE36 HRLl LTGS HOP2 ASH2 MNR2 FWKl
Kiln Output(Tpd)
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120
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m 1991
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PRECALCINER KILN
Maintenance Costs .
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WORI :S
Blue Circle Cement
PROCESS
ENGINEERING
TRAINING PROGRAM
MODULE 3
Section 3
Technical Objectives
(Blue Circle Job Description- Process Engineer)
Blue Circle Job Description
Job Described Process Engineer
Operating Group Blue Circle Cement Works Atlanta
Prepared By Rob Davies Incumbent Keith Crowley
Approved By __________________ Date 30 Oct 1996
1. Position in Organization
Vice President of Operations
Operations Manager Corporate Process Manager
Department Managers Process Manager
Process Engineer
2. Job Objectives
2.1 Support
The role of the Process Engineer is to provide technical support to the Production Department in achieving
its objectives of maximizing plant production of quality controlled cement in the most efficient and cost
effective manner.
2.2 Optimization
Optimization of process areas should be thoroughly investigated by testing, data gathering, and the
application of in-house technical expertise to provide progressive solutions to enable continual
improvement in all aspect of the production process.
3. Tasks and Responsibilities
3.1 Main Duties
Routine plant measurements
Calculation and interpretation of results
Preparation of self ignited reports
Recommendation of actions
Advise and assist the Production Manager in the attainment of departmental objectives
Identification and elimination of plant bottlenecks
Validate plant instrumentation by structured plant testing program
3.1.1 Daily
Logging and reporting of process related data in structured database
Analysis of process related data for trends and deviations, taking corrective actions as appropriate
Maintenance of the LINKman control system and associated PLC’s as applicable
3.1.2 Weekly
Review the chemical and physical data for raw mill feed
Review the chemical and physical data for raw mills, advise as necessary
Review the chemical and physical data for kilns, advise as necessary
Review the chemical and physical data for coal mills, advise as necessary
Review the chemical and physical data for cement mills, advise as necessary
Record and interpret the weekly power reading on main plant items
Reflect on the plant performance over the last week, plan for next week
3.1.3 Monthly
Report on plant performance to Production Manager
Complete heat and mass balance, plate velocity and undergrate pressure balance on each cooler
Internal inspection and circulating load on each raw mill, maintaining media levels as required
Internal inspection and circulating load on each cement mill, maintaining media levels as required
Review clinker granulometry of each kiln
Burner Momentum analysis on each kiln
Inleaking air survey across back end dedusting system of each kiln
Monitor blending system performance and conduct equipment survey
Verify each kiln feed wieghfeeder for accuracy
Reflect on the plant performance over the last month, plan for next month
3.1.4 Quarterly
Complete heat and mass balance and inleaking air survey on each raw mill
Axial sampling on each raw mill
Complete heat and mass balance on each kiln
Verify kiln shell scanner by use of hand held pyrometer
Complete heat and mass balance and inleaking air survey on each coal mill
Complete heat and mass balance and inleaking air survey on each cement mill
Axial sampling on each cement mill
Monitor media wear rates for all ball mills
Summarize plant power consumption for each main plant item
Verify each and every Weighfeeder for accuracy
3.1.5 Annually
Inspection, recording and photography of all equipment items
Record results of drilling of refractory, updating refractory database and charts
Weigh and record chain weights, monitoring wear patterns
Grinding media reclassification, order additional media as required
Blending silo performance analysis by use of tracer tests
Reflect on the plant performance over the last year, plan for next year
3.1.6 Stoppages
Inspection, recording and photography of all damaged or worn equipment items
3.2 Occasional Duties
Plant uprating projects, assist in commissioning and ensuring equipment is installed and operated correctly
Support the formulation of the Improvement Plans and Capital Budget by compiling data and calculations
as required
Monitoring the performance of all process control loops, communicating with instrument department any
problems
Trouble shooting of process-related problems and short term bottlenecks, providing information and
solutions
Communicate with operators and first line production supervisors on all production related problems
Preparing training for production personnel
Inspection, photography and reporting on all plant areas during shutdowns
Prepare and update list of pending work for forthcoming shutdowns
Prepare graphs and reports as required for management
Prepare new or revise existing operating procedures to solve problems and prevent recurrence thus
improving plant efficiency
Kiln Process Database
Refractory Database
Tuning of LINKman
Production Training Program
3.3 Creative Work and Projects

Provide technical concurrence on process projects for Improvement Plan
Provide technical assistance as required by Management, for short and medium term process optimization
studies
Any involvement in long-term projects should be restricted to 10% of time, thus focusing on the day to
day optimization workload
3.4 Working Environment

Approximately 25% Office Work, 45% Field Work, 30% Control Room Work
The Process Engineer is frequently expected to carry out investigative work and process measurements in
hot, dusty and unpleasant environments. Due to the operational characteristics of the process it will be
expected that expected that, extended periods of work will be required periodically.
4 Education and Experience

4.1 Essential Education
Bachelor Degree level, preferably in Chemical Engineering or equivalent engineering or scientific course
4.2 Desired Education and Experience

Process Engineering Training Program in USA
In house training on Cement Technology Course in UK
LINKman user training
Chartered Engineer or equivalent Professional Engineer status with relevant institution
Visits to other cement manufacturing operations within BCC group
Computer literacy essential
5 Attributes
5.1 Problem solving
Prompt assessment of the process problems and recommendation of actions or practical solutions are
prerequisites of the jobholder. The consequences of misinterpretation of data or incorrect advice are
invariably production loss and/or plant shutdown.
Commissioning work in particular requires the jobholder to be particularly resourceful, drawing on
previous experience under typically stressful situation. Rapid appraisal of all information from plant and
personnel is required and the ability to communicate effectively is vital.
5.2 Engineering Principles

The application of fundamental process engineering principles and analytical techniques is essential in the
reduction of works operating costs, completion of plant uprating projects, debottlenecking and
troubleshooting projects.
5.3 Discretion
The jobholder exercises considerable discretion in defining the specific areas of process and projects
requiring attention, within the broad framework laid out by the Production Manager. All work requires a
high degree of self-motivation and initiative in defining and categorizing the priorities, allowing the hob
holder discretion in organizing time and resources in an effective manner. The jobholder will, in time, be
exposed to confidential company information and needs to respect the company’s confidence and exercise
considerable discretion, particularly in discussions with outside parties.
6 Relationships
6.1 Supervisory Responsibilities
Co-operation of the first line production supervisors and control room personnel is essential and requires
the jobholder to exercise considerable tact in influencing personnel to comply with operational
requirements. During commissioning the jobholder will frequently be required to make decisions and
distribute tasks to all involved personnel, implying under these circumstances a supervisory role.
6.2 Internal Relationships

Informal and formal discussion the Production Manager, other Departmental Managers, Production
Department personnel, Laboratory personnel and other crafts-people
Training, advising and exchanging information with the control room personnel
Liaise and cooperate with process operators during plant investigations
Exchange latest technology and experience with Blue Circle Technical Center Personnel
6.3 External Relationships

Relationships will need to be developed with plant suppliers during the pursuit of new projects and when
obtaining data and specifications on existing equipment. The confidence of commercial information
exchange needs to be respected.
7 Influence on Company Performance

Productivity, plant modification, elimination of process bottlenecks; process efficiency and control
improvements are all key features of the job. Consequently the influence of the holders actions and
recommendations has wide reaching implications and can result in considerable annul production benefits
and cost savings. Errors in technical, engineering or professional judgment on the other hand would result
in increased production costs, loss of output, efficiency, and potential plant shutdowns. Process
investigations influence the apportionment of the capital budget and deployment of personnel.
8 Development Plan
Objective
Develop Keith to be a technically competent Process Engineer, equipping him with process knowledge,
experience, and interpersonal skills.
LINKman Graphic Toolkit Training

Commissioning Champion and Systems Engineer
ABB CIMS Systems Engineer
Time Management TMI and R. Davies mentoring
Interpersonal Skills AMA
Process Engineering Training Completion of SOP’s and Module Reports
Project Management BCC Project Management Seminar

9. Personal Performance Objectives
Performance Period November to December 1996
No. Accountability Measurable Weight
1 Safety Promotion Support and attend a Safety talk per shift 10%
Operate the plant in a safe and efficient manner
Promote use of PPE by employees
2 Manpower Development Support and attend the Production Technical Training 10%
Acquire LINKman understanding and utilization skills
Acquire CIMS understanding and utilization skills
3 Teaming Development Promotion of SDWT Culture within Department and Plant 10%
Acquire Facilitator Skills for Team development
Facilitate the teaming development within department
Support monthly department communication meetings
4 Overall Plant Performance Total Clinker Produced 107,618 tons 15%

for the period defined Total Raw Mix Produced 182,131 tons
Total Cement Produced 134,801 tones
Kiln 12 month rolling avg MTBS 250 hrs
Landfill Gas Utilization >90%
LINKman run time >95%
5 Project Group Goals Raw Mill 2 t/h type I 145.0 t/h 20%
Kiln 1 t/h type I 39.5 t/h
Kiln 2 t/h type I 39.5 t/h
Finish Mill 2 t/h type I 54.2 t/h
Kiln Fuel Consumption 4.05 Mbtu/t
Raw Mill 2 Mbtu/t type I 0.135 Mbtu/t
6 Project Implementation Support Project development work 20%

LINKman Graphic commissioning
CIMS commissioning
Kiln Inlet Spray-water system commissioning
Spitzer trap commissioning
Kiln Camera Pyrometer Commissioning
7 Housekeeping Maintain engineering office in a clean condition 5%

General Plant Appearance and cleaning up all self generated spills
Support plant philosophy of clean, seal leaks, re-clean and monitor
Respond to environmental issues in a conscientious manner
8 Interdepartmental Cooperation Proactively Identify Maintenance Needs 10%

Promote Quality Control
Ensure instruments truly reflect plant operation
TOTAL EVALUATION 100%

Blue Circle Cement
PROCESS
ENGINEERING
TRAINING PROGRAM
MODULE 3
Section 4
Generic Job Profile

(Process Engineer)
SUCCESS THROUGH PEOPLE
JOB DESCRIPTION REPORT
BLUE CIRCLE CEMENT
Process Engineer
JOB DETAILS
Organization: Blue Circle Cement
Location: all plant sites
Reports to: Production Manager
MAIN PURPOSE OF JOB

To assist the plant management team in identification, analysis and design of improvement
opportunities.
JOB OBJECTIVES
1. To serve as a role model in the areas of leadership, teamwork, customer focus, continuous
improvement, safety, and environmental stewardship to ensure alignment with the company’s
vision and critical success factors.
2. To initiate, develop and implement plant improvement projects.
3. To provide expertise and technical knowledge to plant personnel.
4. To maintain/further develop expertise and proficiency in cement production knowledge.
5. To identify and implement projects that improve quality and/or reduce plant operating costs.
SPECIAL REQUIREMENTS
Education level preferred: College degree: BA, BS
Job related formal training: 1-3 months
Job related work experience: 1-3 years
Other requirements: Cement technology knowledge
Computer skills: MS Word, Excel
JOB DESCRIPTION REPORT Work Profile
Process Engineer 2/23/00 Page 2
ESSENTIAL WORK ACTIVITIES
A4: REVIEWING / EVALUATING
Reviewing systems or processes to assess adequacy

Reviewing efficiency of an operation
Evaluating the practical feasibility of a project
Evaluating the cost of a project or venture
Evaluating installation of complex systems
Reviewing progress of a case or project
Evaluating alternative methods
Identifying problems in a project design
Evaluating numerical data on organization or dept.
Evaluating written reports on organization or dept.
Reviewing to assess compliance with rules, laws, etc.
Assessing feasibility or practicality of an operation
D2: PROBLEM SOLVING / DESIGNING
Finding ways to improve efficiency of an operation

Suggesting new solutions to production problems
Generating solutions to problems with equipment
Thinking up new systems or procedures
Originating processing or equipment design
E2: ANALYZING / DIAGNOSING
Diagnosing problems in physical process or machinery

Identifying patterns or trends within data
Analyzing numerical information
Using formalized analysis (e.g., network, critical path)
Breaking down a procedure into logical steps
Analyzing written information
C1: INVESTIGATING / OBSERVING / SEARCHING
Watching an operation or process to detect a problem

Watching for dangerous situations
Reading a complex plan or diagram
Noting unusual occurrences
Asking questions to establish information required
Establishing information for proof, validation or evidence
E1: ASSESSING / EVALUATING
Evaluating quality of output of a production system

Testing a system for correct functioning
Assessing probability or likelihood of an event
Critically examining information for accuracy / quality
JOB DESCRIPTION REPORT Work Profile
A1: PLANNING
Planning a logical sequence of events or tasks

Ensuring component parts fit overall project design
Preparing a specification for a project
Planning long term (strategic) objectives
Planning short term (task) objectives
A2: IMPLEMENTING / COORDINATING
Ensuring efficient coordination of activities

Organizing resources to meet an objective
B2: APPRAISING / EVALUATING
Creating confidence among those learning new skills

Demonstrating procedures to help others
Helping others to produce ideas
Undertaking on the job training of others
Developing learning or training exercises
Considering appropriate staff development action
B7: COOPERATING / ACTING AS A LIAISON
Acting as liaison with supervisors

Acting as liaison between organizations or departments
Cooperating on joint projects with other groups
Achieving cooperation from peers, colleagues
F2: PRESENTING / INSTRUCTING / BRIEFING
Explaining systems, procedures or controls to others

Instructing in the use of tools or equipment
Explaining theory to students or trainees
Briefing individuals on tasks or situations
Explaining specialist topics to non-specialists
JOB DESCRIPTION REPORT Work Context
INTERPERSONAL CONTACT
The graphs below show the nature, type and frequency of interpersonal contact required.
CONTACT WITH WHOM?
Sr. Mngmt.
Mid. Mgmt
Jr. Mgmt.
Supervisors
Admin. Staff
Manual Workers
Gen. Public
Student/Trainee
Union Reps.
1 2 3 4
Key
1: None
2: Occasional (1-9 % of time)
3: Moderate (10-20 % of time)
4: Frequent (21% + of time)
TYPE OF CONTACT
Informing
Phy. Serving
Directing
Persuading
Negotiating
F. Speaking
Advising
Assessing
Interviewing
Counseling
Representing
1 2 3 4
JOB DESCRIPTION REPORT Work Context
RESPONSIBILITIES
Responsibility for Resources See Relevant Job Statistics
Financial Impact: V. substantial: $600,000-$1,000,000
Functional Impact: Non-routine funcs - major impact
Breadth of Job Knowledge: Knowledge limited to one specific function
Demands of Change: New situations occur occasionally
Time Span of Impact: Moderate term - 1 to 3 months
SPECIFIC ACCOUNTABILITIES
The graph below shows the level of specific accountabilities for this job.
Cash
Equipment
Property
Product Quality
Worker Standard
Finance Results
Public Relation
Work Methods
Others Safety
Innovation
Sales Performance
1 2 3 4
Key
1: None
2: Low
3: Moderate
4: High
JOB DESCRIPTION REPORT Project Details
WORK CONTEXT AND ENVIRONMENT

Type of Working Hours
Regular
Usually day time working
Working Hours
Normal weekly hours................................................ 40
Paid overtime hours ................................................... 0
Unpaid overtime hours ............................................... 5
Total weekly hours ................................................... 45
Travel
Time spent travelling (excl. from/to work).............. 11-25%
Time Away from Home

Nights within home country ................................... 11-20
Nights in other countries ....................................... 1-10
Posture: Percent Time Spent ...
sitting
standing
walking
running
stooping/kneeling
0 10 20 30 40 50 60 70 80 90 100 climbing
Physical Danger
Minor physical injury.............................................. Moderate risk

Serious physical injury........................................... Moderate risk
Physical Environment: Percent Time Spent ...
out of doors
at high temperature
at low temperature
in contaminated air
in noisy conditions
in dirty environment
in a restricted space
with inadequate lighting
with machine vibration
with ear protection
with eye protection
with breathing apparatus
0 10 20 30 40 50 60 70 80 90 100
Blue Circle Cement
PROCESS
ENGINEERING
TRAINING PROGRAM
MODULE 3
Section 5
BCC North America Process Engineering

Training Program
(Sample)
BCC North America Process Engineering Training Program
Objective
The process engineering training program has been developed in modular form to provide
detailed training and practical experience in cement technology and process engineering
skills, and enable clarity of focus on the Process Engineers' role within Blue Circle
Cement.
Schedule
The program is normally scheduled over a period of 8-9 months, with 1 week sessions
based at a works in BCNA. These sessions comprise of both classroom and on the job
training. The pieces of work performed on any particular site are not just exercises for
their own sake. They are planned to be relevant pieces of investigation with conclusions
and, if applicable, specific action points which the works can act upon in order to attain
continuous improvement.
Delivery of the specific technical content will be performed by using the Corporate
Process Engineering team (Keith Rabson and Andy Edwards), with assistance from the
previously trained present Process Engineers as "trainers". Specialist subjects will be
delivered by both in house resources and external companies.
Modules
Each month separate modules of work will be undertaken. Notes will be supplied
typically comprising relevant sections of the CTC notes and recently published papers.
The trainee will be expected to cover all the identified work at their normal work
location, writing up each piece of work for assessment. The focus of the training module
will be to grasp the key concepts and be able to utilize them in a trouble-shooting
scenario.
Assessment
At the end of each month the trainee will be expected to prepare a two page summary of
the key principles they have covered during the month, the purpose being to assess the
Process Engineers' understanding of the principles involved. Any misconceptions can
then be identified and corrected by further training. Once satisfactory understanding has
been demonstrated then this document should be co-signed by the Process Engineer,
Production Manager/Process Manager, and one of the program administrators. This
"Summary Report" can then form the basis of their training record and be used for
application for "Professional Engineering" status should the trainee be motivated to do
so.
Each of the new Process Engineers will be assigned a "Mentor" who should not
necessarily be their line supervisor. The Mentor's role is to coach the trainee, be a point
of reference in training needs and assess the progress of the trainee.
Further Training
Once the training program is underway then opportunities will arise to assess the
individual training needs of each nominee. It is intended that quarterly reviews be held
between the Production Manager/Process Manager, Process Engineer, and one of the
program administrators. It is then suggested that a tailored program be prepared for each
trainee, making use of external courses to supplement the enclosed program.
PET Modules
Module Name Module Number
Introduction to Cement Industry 1

Introduction to Kiln Processes 2
Process Engineering Objectives 3
Process Measurement and Testing 4
Fan Measurement and Testing 5
Process Control in the Cement Industry 6
Electricity in the Cement Industry 7
Heat and Mass Balances 8
Clinker Coolers 9
Raw Milling 10
Coal Mills/Coal Milling 11
Flames 12
Kiln Volatiles 13
Refractories 14
Roll Press 15
Cement Milling 16
Separators 17
Statistical Process Control 18
Material Handling 19
Environmental /Dust Collection 20
Raw Material Blending 21
Chemistry and Quality Control 22
Project Management 23
Financial Management 24
1998 / 99 Program of events
The following is the schedule as done in 1998 / 99.

The next new course will commence in the fall of 1999.
Week 1 October 98 Bowmanville

Introduction to Cement Industry 1
Introduction to Kiln Processes 2
Process Engineering and Objectives 3
Process Measurement and Testing 4
Week 2 November 98 St Marys

Roll Pressing 15
Cement Milling 16
Separators 17
Plant testing # 2 & # 3 finish mills
Week 3 January 99 Bowmanville

Heat and Mass Balances 8
Clinker Coolers 9
Plant testing Cooler heat balance
Week 4 February 99 Atlanta

Electricity in the Cement Industry 7
Process control in the Cement Industry 8
Raw Milling 10
Plant testing Finish mill #2
Week 5 April 99 Bowmanville

Coal Coal Milling 11
Flames 12
Kiln Volatiles 13
Plant testing Kiln system heat balance
Week 6 June 99 Atlanta

Chemistry and Quality Control 22
Refractories 14
Mechanics of kilns
Plant testing Raw Mill
Week 7 July 99 Atlanta

Blending 21
Statistical Process Control 18
Environmental issues
Dust collection 20
Project Management 23
Financial Management 24
Previous course attendees
Name Location as of July 1999 Position

Ann Griffin Roberta Process Engineer
Mark Mueller
Karen Blackwood Corporate CIMS Project Manager
John Kopec Atlanta Production Manager
Karen Trout Bowmanville Process 1Manager
Marco Gonzalez St Marys Process Manager
Jeff Brummert
Paul Rogers Harleyville Process Manager
Keith Crowley Sparrows Point Process Manager
Greg Murray Tulsa Production Manager
Vernon Copley Tulsa Process Engineer
Chuck Kessler Harleyville Process Engineer
Jorge Espinosa Tulsa Process Engineer
Jay Gove Ravena Process Coordinator
Kevin Maylin Bowmanville Process Engineer
Tony Perry Atlanta Process Engineer
Shawn Sullivan St Marys Production Manager
Martin Vroegh Greenhithe, UK Process Engineer
Ron Ward Detroit Production Manager
Melissa Mcleod Sparrows Point Process Engineer
Terry Chigwedere St Marys Process Engineer
Kim Russell Bowmanville Process Engineer
Joe Stratton Bowmanville Instrumentation Technologist
Donald Stewart Atlanta Process Engineer
Blue Circle Cement
PROCESS ENGINEERING TRAINING PROGRAM
HBM PROCESS ENGINEERS

CONFERENCE
• Roberta Kiln Bottlenecks

• Benchmarking Kilns- The New Target
Blue Circle Cement
PROCESS ENGINEERING TRAINING

PROGRAM

CONFERENCE
• Roberta Kiln Bottlenecks

ROBERTA KILN BOTTLENECKS
INTRODUCTION
With the approval of a new 5500 HP cement mill for Roberta, it was realized that the cement
kilns would have to produce 43.5 STPH (39.5 MTPH) in order to supply the new mill sufficient
clinker. At the time when the mill case was approved, the Roberta cement kilns were averaging
37.7 STPH (34.2 MTPH). This posed a great technical challenge to Greenhithe, Corporate, and
plant personnel.
Through teamwork in design and commissioning, several kiln bottlenecks were identified for
improvements. The scope of this paper identifies some of the more successful areas of change
and improvement. Since the winter outage modifications of March 1996, the kilns have been
producing clinker at an average rate of 41.7 STPH (37.8 MTPH). Although the ultimate kiln
capacity goal has not yet been achieved, at least one major project and several minor
modifications remain uncompleted. With the completion of these projects, the capacity increase
of the kilns to 43.5 STPH (39.5 MTPH) should be achieved.
BAGHOUSE OPERATION
When the baghouse operation of the Roberta kilns was investigated, it was found to be one of the
most restrictive variables in terms of increasing kiln output. More draft was required for
increased fresh feed and fuel rates. At this time, the kiln induced draft fan could be opened at a
maximum of 22% indicated damper position before baghouse pressurization problems were
evident. Experimentation with baghouse cycle timing produced little, if any, positive results.
The eventual solution to the baghouse limitation was to install new high pressure developing
reverse air fans. These fans provide better bag cleaning and thus reduce the pressure restriction
on the compartments of the baghouse. This installation allowed the kiln operator to utilize more
capacity of the kiln induced draft fan and add more kiln feed and more fuel for improved output.
INCREASING CHAIN GAS TEMPERATURE

After studying the profile of other long dry kilns which produced greater output of clinker than
similar Blue Circle kilns, it was discovered that those kilns generally had a higher chain gas
temperature than our long dry kilns. In fact, Ravena's wet kilns maintained a temperature of
1900°F to 2000°F (1038°C to 1093°C) in this area. Maintaining a higher temperature for this
kiln area made sense. It encourages more raw meal preparation around the chain section of the
kiln. This is a similar principle to what is accomplished by more efficient kiln systems such as
the precalciner and preheater kilns. More raw meal preparation is equivalent to increased kiln
output.
The chain gas temperatures of the kilns have been increased from around 1550°F to around
1600°F (843°C to 571°C). We have noticed that the kilns are more stable with less tendency to
flush if the chain gas temperature is maintained around 1600°F (871°C). We are continuing to
increase the chain gas temperature to levels up to 1700°F (927°C).
WATER SPRAY SYSTEMS
In order to reduce dust loss, the speed of our kilns was reduced. This strategy allowed for a
higher chain gas temperature, a higher back end temperature, and subsequently a higher kiln
baghouse temperature than with the previous kiln operation. In order to protect the kiln
baghouse, a reliable water spray system was needed.
The old kiln water spray systems consisted of a water pump and a compressor for atomization
air. The compressors were reaching service lives of 2.5 years and were near the end of their
useful life expectancy. Maintenance costs for these compressors were high. Furthermore,
problems often occurred when one of the compressors would go down causing production losses.
A decision was made to install efficient, high pressure water spray pumps similar to the ones
installed at Tulsa. The result was a twofold benefit. First, the water was atomized in a better
fashion using higher pressure water. This resulted in less water usage and lower back end
temperatures. Secondly, this new water spray system eliminated the costly atomization air
compressors presenting both power and maintenance savings.
KILN FEED SYSTEM

It has been recognized for some time that dust loss is the limiting factor of increased clinker
output on long dry kilns. Any process change to the kiln system could have a direct effect on the
dust loss of the kiln and ultimately the clinker output. Therefore, the kiln system should have
some means of measuring dust loss as these changes are performed.
The previous arrangement of the Roberta kiln feed systems were to return the dust and fresh feed
to each of the kilns together. This posed the problem of not knowing how much dust was being
generated by each kiln and how much dust was being returned to each kiln. A new kiln feed
system was devised so that the dust loss on each of the kilns could be measured independently.
The new feed modifications mimicked the independent dust return designs of the Tulsa kilns.
However, this system utilizes nuclear scaling devices to weigh the dust captured and returned by
each kiln’s buell system. This system is critical to detect the efficiency of dust return to the kilns
and to gauge the amount of dust generated by process moves such as increased damper settings
on the induced draft fans.
DUST RECIRCULATION HANDLING

In addition to the lack of information concerning the dust returned to the kilns, the buells were in
poor mechanical condition. Hoppers had cracks which allowed water to get inside and caused
plugging and build up on the sides of the hoppers. The cement kiln feeder man used to have to
spend countless hours clearing a plugged hopper after a rain storm. This resulted in a unsteady
kiln operation due to erratic dust return.
The hopper tipping valves were also in poor mechanical condition. After the last winter outage,
another set of poor quality tipping valves were installed to replace the previous valves. These
valves were locally fabricated and relatively inexpensive compared to proper valves. The results
of using the valves have been disastrous to our process. We noticed that the flap plates, which
were only tack welded to the pivot bar, were breaking and blocking the entrance to the conveying
screws below the hopper chutes. As a result, most of the flaps were tied in an open position until
they could be repaired during a kiln stop. The process results were erratic dust return?
overburdening of the kiln baghouse, and large amounts of inleaking air. The present single flap
gravity tipping valves will be replaced by motorized double tipping valves which will regulate a
steady flow of dust to the kilns and reduce inleaking air. Isolation valves will also be fitted
above each of the tipping valves so that they may be maintained while the kiln is running.
Another shortcoming of both buell systems was the collecting screw capacity. This screw
transports dust from all buells and hoppers to the dust elevator feed screw. It was discovered that
both kiln collecting screws were not rated with sufficient capacity to remove the dust load
captured by the buells and hoppers. This situation has been remedied on one of our kilns by the
installation of a new reducer which will allow the collecting screw to move faster and thus carry
more material.
COOLERS
The coolers of both kilns have given satisfactory performance in the past with lower demands of
clinker capacity. However, the first two cooler fans would lose pressure capability when the kiln
lost nose coating or the cooler experienced a kiln flush. A decision was made to uprate the first
two chamber cooler fans to promote the pressure capability of the cooler to cope with increased
clinker production and a deeper clinker bed depth.
Presently, the coolers are operating with an average recuperation zone bed depth of 13 inches
(330 mm). The new limitation of the coolers for running a deeper bed of clinker in the
recuperation zone is the stall speed of the primary grate drive. Efforts will be made to reduce the
effective area of the recuperation zone to encourage a deeper bed of clinker in the absence of
installing high efficiency grate technology.
FUEL AND FIRING SYSTEM

A supply of good quality sufficiently dry coal is necessary for the success of any kiln operation.
Investigations were made to ensure the consistent supply of quality coal to the plant. The plant
coal supply was limited to two fuel suppliers that could guarantee the plants demands of fuel
quality.
Once a good quality coal is received at Roberta, we are at the mercy of the weather to maintain
its dry status. This is due to the fact that the fuel supply stockpiles at Roberta are uncovered.
This results in numerous coal mill interruptions at reduced production rates after periods of
heavy rains and the use of increased quantities of primary air from the cooler to dry the coal to
sufficient firing specifications. In the immediate future, the supply of coal will be protected from
the elements by constructing a covered coal storage area, similar to Harleyville’s installation,
capable of storing at least two weeks supply of dry coal.
In order to deliver the pulverized fuel to the kiln, the fan blades of both kiln’s coal mill fans were
tipped out to the maximum extension to encourage higher pressure capability of the fan. This
occurred in conjunction with the standardization of the firing pipe design at Roberta. The
previous design included a continuous 5 inch diameter gas pipe through the inside of the firing
pipe. This caused a restriction at the goose neck of the firing pipe and was a source of high
pressure loss and extreme wear. Both burner pipes were modified and to allow a 3 inch (76 mm)
diameter gas pipe with a 5 inch (127 mm) diameter bluff body at the end of the internal gas pipe
to develop a sufficient tip velocity.
THE RESULTS
A team effort has improved the output of both kilns at Roberta. As a result of the work, the plant
is closer to the goal of being able to supply enough clinker to the new cement mill for cement
grinding. This is extremely important during a time of “sold out” market conditions such as our
present market condition.
The last major project which has to be completed is the blending and storage modifications to
our blending silos. This will help to deliver a consistent raw mix to the kilns. It has been
estimated that this improvement is valued at 1.4 STPH (1.27 MTPH). As stated earlier, the kilns
are presently producing 4 1.7 STPH (37.8 MTPH) and it can be seen that the blending silo project
and the remaining minor projects will contribute greatly to achieve our goal.
Blue Circle Cement

PROGRAM

CONFERENCE
• Benchmarking Kilns –
The New Target
BENCHMARKING KILNS - THE NEW TARGETS
Blue Circle has been benchmarking kiln performance formally since 1973, when the
Walker/Watson targets were introduced. This was by no means the first attempt to calculate the
theoretical maximum output of kilns and Gygi, Anselm and Weber all attempted to lay the
theoretical basis for kiln design during the 1960s. However, the conversion of theory to reality
proved difficult and the more pragmatic Blue Circle approach has been shown to be more useful.
There were several reasons for the recent re-evaluation of the Walker/Watson targets.
i) The best day/best week data on which they were based was often of dubious value.
ii) Considerable advances had been made on precalciner kiln outputs.
iii) It was now evident that preheater/precalciner kilns were currently limited by hearth
velocity.
iv) More accurate data on long dry kilns is now available.
These problems have been addressed and best month data was selected as the most appropriate
benchmark. Targets have been produced for each process and, with the exception of the Lepol
process, the kiln tube dimensions are the sole determining limit. It has been assumed that all
ancillaries can be siied to meet this limit ifmaximum production is required.
Wet Process
The original limit on this process was set by a combination of heat transfer/dust loss limits but
Ravena has been so success&l at increasing production on a relatively short wet process kiln that
the original heat transfer limit has now been exceeded by 30% and has been discarded for the
current benchmarks. Only when the hot end of chain system is being rapidly destroyed by
temperature can the heat transfer limit be re-applied. There is some evidence that this day is not
too far removed at Ravena.
There are some difficulties in using the velocity limit on wet process kilns as there are
differences in the fiiability index of raw materials which will influence the nodule strength and
thus tendency of the nodules to break down in the chain system. Thus poor, high friability index
materials will give higher dust loss at a given gas velocity and potentially lower outputs.
However, over recent years we have made good progress with dust return and scoops are now
in widespread use. This has allowed higher gross dust loss to be tolerated in a way which was
not possible with insufflation and poor materials are not thus an immediate problem. Finally,
though it will be found that the new, higher gross dust loss limit will again be encountered at
higher production and this will occur at lower gas velocities at Ravena and Masons than at
Northfleet (wet), Westbury and Ewekoro.
The velocity limit (110 t/d/m2 which has been set is disappointing in that the benchmark has
been set by Norman Works, which was shut down in the 1970s. One major difference between
this and the previous limit is that it does not represent a fixed gas velocity. The reasoning is that
the increased velocity in high fuel consumption/high feed moisture kilns will be compensated
by higher in-chain moistures and lower friabilities leading to less dust formation in the chain
Dry Process
The situation is much more straight-forward with long dry kilns. Little has changed in the
technology since the 1970s and material friability has little or no effect. Chain gas inlet
temperatures are well below those encountered on the better wet process kilns and high
temperature wear is not a serious issue. As such heat transfer has not yet been considered a limit
mit As no wet zone or nodular
for long dry kilns. What remains is the gas velocity/dust loss limit
material exists in the chains the vast majority of raw meal could be theoretically entrained and
the velocity limit is lower for long dry kilns than for wets. Many long dry kilns are achieving
close to the 93 t/d/m2 which is the benchmark, but the penalty is very high gross dust loss of up
to 50% on raw feed. Although chain system optimisation may give some benefits it is difficult
to see much progress beyond this benchmark without pelletising kiln feed such as practised in
some Italcementi kilns.
Preheater Process
For preheater kilns the previous target was established by the combination of heat transfer and
kiln body velocity limits. Neither of these appear, under current conditions, to be the actual
reason for restriction of preheater kiln outputs. A heat transfer limit would imply that kiln exit
temperatures reached an upper limit, but the wide range of temperatures found in practice (1 000-
1400°C) seem to have little effect on the preheater temperature profile and thus any imposition
on kiln output. The only problems which arise are the reduced life of back end and riser
refractory and hearth castings.
The preheater kiln velocity limit also appears to be insignificant. Dust generation within the
body of the kiln is relatively low unless rings are present, and there is no evidence to support the
theory that dust loss from the kiln places a restriction on kiln output. What has been frequently
demonstrated is that raw meal pickup at the kiln hearth will cause radical changes to both
preheater suctions and temperatures and that the gas velocity in this area is the single largest
cause of restriction to kiln output. A limiting velocity of 34 m/s at a notional temperature of
1150 C has been selected as a target.
Precalciner Process
At the time when the previous targets were set there were relatively few examples of precalciner
kilns within the Blue Circle group and considerable doubt about the data available on the
Japanese and German kilns in existence at the time. As a result the targets for Air Through and
Air Separate kilns were ill-defined. Operating practice has since demonstrated that the heat
transfer and kiln body velocity limits are again of doubtful value. That heat transfer was not a
factor has been well demonstrated by the short L:D ratio kilns of KHD achieving heat transfer
ratings of 20+% over standard kilns. Kiln gas velocity has also not been shown to have an
impact but there is some evidence emerging that hearth velocity limits are again the limiting
factor for precalciner kilns. For reasons which are not well understood hearth velocities of 34
m/s are achievable on Air Through kilns but only 30 m/s on Air Separates. With a dearth of AT
kilns in Blue Circle little more specific data is available on the process differences which could
explain the lower achievable velocities for AS.
Semi Dry Process
Polysius limits on the Lepol kilns are very specific and eliite the kiln size entirely as a
limiting factor Their highest standard, 14.5 t/d/m2 of Lepol grate area, is only achieved with the
best materials. It is accepted that nodule friability and strength play a major role in the
permeability of the nodule bed on the grate. Thus poor material nodules will break down and
restrict gas flow through the bed, ultimately reducing coal flow and thus expected kiln
production. Good nodules are thus essential and avoidance of cyclone, precipitator and riddlings
dust being returned to the kiln system will increase gas flow through the bed.
General Conclusions
The overall objectives of this type of evaluation are to establish the true bottlenecks within the
kiln system and give a target output for a given process. For many works there will be factors
which restrict the kiln from achieving its full potential below these targets. Typical examples
would be ID fans, precipitators, coolers and coal milling. For the majority of plants, when the
situation requires higher production and capital is available, it is essential to develop a plan to
progressively remove these bottlenecks and achieve higher outputs.
But the emphasis also remains on doing the simple things well - Ensure our operators are trained
to an excellent standard, tune LINKman or other kiln control systems, ensure the kiln feed has
a stable, burnable chemistry and avoid kiln stops. By these and many other means the difference
between the kiln best tonnage and average can be reduced.
For some plants we have the ability to challenge these targets and establish new benchmarks.
There are many areas in which we can attempt to advance kiln technology and some of these are
discussed in the papers which follow, i.e.
hearth design
minimising dust generation in chained kilns
- dust return methods
BENCHMARKING
KILN OUTPUTS
-THE NEW TARGETS

PREVIOUS PRODUCTION
TARGETS
l Gygi, Anselm & Weber theoretical models

in 1960’s
o Walker/Watson 1973 practical targets based

on best achieved outputs for kiln tubes
REASONS FOR
RE-EVALUATION
a Best day/best week data used was of
dubious value
l Precalciner kiln knowledge much advanced
l More accurate data on long drys available
l Evidence that previous theories of heat
transfer/dust lost limit flawed
l Evidence that preheater/precalciner kilns
hearth velocity limited
I
BASIS OF NEW TARGETS
l Kiln tube dimensions only wet and long dry
l Hearth area thus implied kiln tube

dimensions for preheater and precalciner
te only for LEPOL process
ance
l Annual average target = 0.97 x best month
WET PROCESS
a Heat transfer limit exceeded by 30% at
Ravena with some reduction in chain life
thus not used in new targets
l Dust loss limit determined by gas velocity
and material friability
l Present experience gives balance between

velocity and ftyability thus 110t/d/m2 c.s.a.
new limit
l Set by Norman Works in 1970’s
WET PROCESS KILNS 2
TARGET OUTPUTS Q
Kiln Target t/d Average 1994
Masons 5 1195 1070

Northfleet 2 2370 2196
Northfleet 4 2370 1772
Westbury 1 1195 1037
Westbury 2 1195 1102
Ewekoro 3 1195 624
Shagamu 1 1490 1299
Shagamu 2 1490 1257
Ravena 1 2805 2276
Ravena 2 2605 2366
LONG DRY
l No known heat transfer limit determined
l No friability or nodule quality effects
a Tolerable gas velocity lower than wet as no

nodules present
l Target 93t/d/m2
l Set by Wagerstown, Yanbu

LONG DRY PROCESS KILNS
TARGETOUTPUTS x 0 47
t&-k-.
7’.
.--1-v
.
Melon 8 819 701
Atlanta 1 1094
Atlanta 2 1094 816

Roberta 3 1094 806
Roberta 4 1094 827
Tulsa 1 1094 831
Tulsa 2 1094 841
PREHEATER KILNS
l Heat transfer variable but no indication this
is a limit
a Velocity of gases in kiln body not significant

in dust generation
l Hearth velocity causes restriction to kiln

output where no other bottlenecks are apparent
SP KILN HEARTH VELOCITY
VS. KILN DIAMETER
20
3 4 5 6 7
Kiln Diameter(m)
PREHEATER KILNS
TARGET OUTPUTS
1 Kiln Target t/d 1 Average 1994 1

Aberthaw 6 1810 1466
Hope 1 2540 1836
Hope 2 2540 1784
Plymstock 2 1350 977
Ashaka 1 1315 1242
Ashaka 2 1196
Harleyville 1 1915
Manresa 2 893
PRECALCINER K I L N S
l Former heat transfer limit 20% exceeded by

KHD Pyrorapid thus ignore heat transfer limit
o Kiln body gas velocity not a limit
l As with preheater kilns bottleneck is hearth

velocity
PC-AS KILN HEARTH VELOCITY

VS. DIAMETER
40
t 30
20
$01
3.25 a.75 1.26 4.76 6.2s 5.76 a76
AS PRECALCINER KILNS
TARGET OUTPUTS
Melon 9 2295 1730
Cauldon 1 3135 2662
Dunbar 1 3705 2749
Kanthan 3 3765 3239
Rawang 3 5200 4654
LONG (SEMI-DRY) KILNS

o Polysius have no limit on kiln heat transfer or
kiln gas velocity
a Thus LEPOL grate area only effective limit
e Nodule friability and strength very important
a Dust (cyclones, riddlings, precipitator) must

be removed
LEPOL KILNS
TARGET OUTPUTS
Weardale 1 1578 1384
Weardale 2 1578 1003
Cookstown 1578 1141
NEW TARGETS - OBJECTIVES
o Identify full potential output of kiln
a Identify and remove, when appropriate and

cost effective, the ancillary bottlenecks
BUT
l Do the simple things well
i.e:
- Train operators
- Tune and use kiln control system
- Ensure kiln feed chemistry stable

and burnable
- Avoid kiln stops
THE FUTURE
BREAK THE MOULD!
l Optimise wet and long dry dust generation

and return systems
o Devise and install new hearth layouts

Blue Circle Cement

PROGRAM
PRESENTATIONS
Benchmarking –
Colin Paxton
Process Engineers Conference
Output Targets and Benchmarking

Blue Circle Cement

PROGRAM
PRESENTATION
Benchmarking
- Colin Paxton
BENCHMARKING
COLIN PAXTON
OVERVIEW
• INTRODUCTION TO
BENCHMARKING
• BENCHMARKING CEMENT PLANT

OPERATION
• BCI TECHNICAL BENCHMARKS

INTRODUCTION TO
BENCHMARKING
• WHAT IS BENCHMARKING ?
• Process of comparison, aimed at achieving
TOP CLASS performance
– similar operations, including competitors
– Establish own performance against “best”
– Helps to identify improvement opportunities
– Can refer to businesses, people, equipment,
processes, etc
BENCHMARKING
• SET OBJECTIVE
• IDENTIFY KEY PERFORMANCE

INDICATORS (KPI)
• COMPARE KPI WITH BEST PERFORMANCE
• SET TARGET PERFORMANCE LEVELS
• IDENTIFY IMPROVEMENT OPPORTUNITIES

BENCHMARKING
CEMENT PLANT OPERATION
• WHAT IS OUR OBJECTIVE ?

CEMENT PLANT
• KEY PERFORMANCE INDICATORS

– PLANT PRODUCTION TPD
– PLANT AVAILABILITY
– FUEL CONSUMPTION
– POWER CONSUMPTION
– MAINTENANCE COST
– REFRACTORY CONSUMPTION
– COST OF KILN FUEL
– ENVIRONMENTAL PERFORMANCE
EQUIPMENT RATINGS
• PC PROCESS KILNS
– Comparison of kilns of different sizes ?
– Use of target output from process limits
– Compare % of target output
Maximum gas
velocity 30 m/s
KILN PRODUCTION
P R E C ALC INE R P R OC E S S OU TP U T
(% OF TAR GE T) ANNU AL AV E R AGE
100 1995
1996
90
1997
80
70
60
(% )
50
40
30
20
10
0
LTG 5 R WN3 B MV3 K N T3 C LD 1 D NB 1 MLN 9 LTG 6 A TR 3
KILN AVAILABILITY
1995
PR EC ALC INER PR O C ES S
(%) KILN RUNNING TIME 1996
1997
> 4.5m S he ll dia . < 4 .5 m S h e ll

100
Ta rge t 87% running time
Ta rge t 90% running time
90
80
70
60
(% )
50
40
30
20
10
0
R WN 3 B MV MLN 9 K N T3 C LD 1 LTG 6 D N B 1 LTG 5 ATR 3
MEAN TIME BETWEEN
STOPS
P R EC A LC INER P R O C ES S
300 1995
280 1996
260 1997
240
220
200
180
(h rs .)
160
140
120
100
80
60
40
20
0
MLN 9 K N T3 C LD 1 B MV 3 R WN3 D NB 1 LTG 5 LTG 6 A TR 3
FUEL CONSUMPTION
P R E C A LC IN E R P R O C E S S
1100 1995
1996
1000
1997
900
800
700
k c a l/k g
600
500
400
300
200
100
0
MLN 9 C LD 1 D NB 1 R WN3 K N T3 B MV 3 LTG 5 A TR 3 LTG 6
(kW h /to n n e
0
50
100
150
200
250
BMB 300
EW K
S HR
WST
MLN
KNT
MS N
RW N
C KS
RV N
A LB
W RD
1995
G DB
A SH
S HG
1996
C LD
W o rks
TLS
S TM
1997
LTG
A TL
NR T
HO P
A TR
A BR
DNB
MNR
HR L
POWER CONSUMPTION
BMV
PLM
RB T
RA K
REFRACTORY
CONSUMPTION
PR EC A LC IN E R PR O C E S S 1995
K ILN R EFR AC TO R Y U S A G E (g /t) 1996
1997
2200
2100
2000
1900
1800
1700
1600
1500
1400
1300
1200
(g /t)
1100
1000
900
800
700
600
500
400
300
200
100
0
C LD 1 MLN 9 B MV3 K N T3 R WN 3 D NB 1 LTG 6 LTG 5 ATR 3
Maintenance Costs
12
10
(87.2)
8
(£/tonne)
0
KNT
NRT
WST
RBT
ATR
RWN
CLD
ABR
ASH
WRD
RVN
MSN
MLN
MNR
HRL
ATL
LTG
SHG
STM
PLM
BMV
ALB
CKS
BMB
EWK
DNB
GDB
HOP
TLS
Cost of Maintenance materials Cost of Kiln Refractory materials Cost of Kiln Chains materials
Cost of Contractors Maint. materials Cost of Maintenance Contractors Cost of Own Workforce
If you know your enemy
and you know yourself,
you need not fear the outcome
of a hundred battles.
THE END
Blue Circle Cement

PROGRAM
PRESENTATION
Process Engineer Role

PROCESS ENGINEERS
CONFERENCE
BLUE CIRCLE CEMENT
MARIETTA U.S.A
PROCESS ENGINEERS
HOW CAN THE ROLE BE
MADE MORE EFFECTIVE ?
BENCHMARK AREAS
✦ PROCESS EFFICIENCY
✦ CAPACITY
✦ M.T.B.S
✸ RAW MATERIALS PREPARATION

✸ RAW MEAL PREPARATION
✸ KILN , FIRING & COOLER
SYSTEMS
✸ CEMENT MILLING
OUR RESOURCES
✦ PLANT TEAM
→ OPERATIONS MANAGER
→ PROCESS MANAGER
→ PROCESS ENGINEER
→ MANAGEMENT TEAM
→ OPERATIONAL STAFF
✦ OTHER PLANTS’ STAFF

✦ B.C.T.C. - GREENHITHE
PRIME OBJECTIVES
✦ 1. MAXIMIZE PRODUCTION T.P.D.
✦ 2. MINIMIZE FUEL CONSUMPTION.
mBtu/Ton
✦ 3. MINIMIZE POWER CONSUMP.
KWh/Ton
✦ 4. INCREASE
MEANTIME
BETWEEN STOPS
PRIME OBJECTIVE
MAXIMIZE PROFITS
✦ 1. MAXIMIZE SALES REVENUE
✦ 2. MINIMIZE FUEL COSTS

✦ 3. MINIMIZE POWER COSTS
✦ 4. REDUCE MAINTENANCE COSTS

U.S.A. JOB ROLE
THE ROLE OF THE PROCESS ENGINEER
IS TO PROVIDE TECHNICAL SUPPORT
TO THE PRODUCTION DEPARTMENT
IN ITS OBJECTIVES OF MAXIMIZING
PLANT PRODUCTION OF QUALITY
CONTROLLED CEMENT IN THE MOST
EFFICIENT AND COST EFFECTIVE
MANNER.
U.K. JOB ROLE
TO BE RESPONSIBLE FOR THE
PROCESS ENGINEERING
INVOLVED IN NORMAL
OPERATION AND DEVELOPMENT
OF CEMENT PROCESSING AT THE
PLANT WITH A VIEW TO
MINIMIZING OPERATING COSTS
AND IMPROVING PRODUCT
QUALITY
A BETTER DESCRIPTION ?
TO INCREASE THE SHORT TERM
PROFITS OF THE COMPANY, AND
TO ADVANCE THE SKILLS AND
KNOWLEDGE OF
CHEMICAL/PROCESS ENGINEERS,
THEREBY INCREASING THE
LONGER TERM EFFICIENCY AND
PROFITS OF THE COMPANY.
OBSTACLES
✦ 1. LACK OF EXPERIENCE
✦ 2. DISTRACTIONS
✦ 3. INCORRECT FUNCTIONS
✦ 4. ATTITUDES
✦ 5. TRAINING
BEWARE !!
“WE HAVE ALWAYS
DONE IT THIS WAY !”
BEST APPROACH
✦ STICK TO THE FACTS NOT OPINIONS
✦ SEEK ADVICE AND SUPPORT
✦ USE OUR SKILLS AND EXPERIENCE

✦ PERFORM REQUIRED MEASUREMENTS
✦ ANALYZE THE RESULTS
✦ MAKE RECOMMENDATIONS
✦ COMMUNICATE , REPORT EFFECTIVELY
BEST APPROACH
DOES WHAT I AM DOING
ADD VALUE ?
Blue Circle Cement

PROGRAM
PRESENTATION
Output Targets and Benchmarking

Output targets and
Benchmarking
CHRIS HOLT
KILN PROCESSES
KILN Kcal/Kg mBtU/st
L/D
1.- Wet Process 23-50 1250-1900 4.7 - 7.1
2.- Semi - Dry 14-20 750-950 2.8 - 3.6
3.- Preheater 12-20 720-950 2.7 - 3.6
4.- Precalciner 10-18 720-850 2.7 - 3.2
5.- Long dry 20-50 900-1350 3.4 - 5.1
6.- Semi Wet 28-40 1000-1300 3.8 - 4.9
Daily Production on days when the
Kiln ran 24 hours
60
50
Number of days
40
30
1041-1060
1061-1080
1081-1100
1101-1120
20
1021-1040
10
0 921 -940 961-980 1001-1020 1121-1140
Tons/day t/d
Factor to the
Annual average
Best day 1148 0.932
Best week 1123 0.953
Best month 1105 0.968
Annual average 1070
Kiln output limitations
* Surface area available for heat transfer.

- We now think that this limit is less important
* Gas velocity for an acceptable dust loss

- Wet process = velocity in the kiln tube
- Semi-Dry process = velocity at the kiln inlet
- Semi-Dry process = Lepol grate loading
Output targets
• BASIS : Kiln tube only
(exception Lepol)
• MAIN USES
– Existing Kilns - Determine limits and
uprating potential
– New Kilns - Review kiln design and the
sizing of auxiliary plant.
Diagramatic - “velocity of gases at
the kiln inlet”
Kiln Shell
this is the point of maximum

velocity, and with the greatest
potential for recirculation
Hearth Velocity on SP kilns
vs kiln Diameter
50
Hearth velocity (m/s)
40
30
20
3 4 5 6 7
KILN DIAMETER (m)
Hearth Area vs Kiln Diameter
10
Hearth Area (m2)
0
3 4 5 5
Kiln Diameter (m)
- y = (0.3038X2)-1.745
Example : Preheater Kilns
PROCESS SURFACE AREA HEARTH

PERFORMANCE VELOCITY
TPD/m2 m/sec
SUSPENSION 2.78 47.4

PREHEATER (RUMELANGE) (GOLDEN BAY)
35.9
(GADOR)
Examples - Preheater kilns
Plant and Kiln dimensions P/H Best Surface area X sect Hearth Target
stages based on
(m) be x bz x length month performance perf velocity
Kiln No t/d
34m/sec at
t/d/m2 m/s hearth tpd
t/d/m2
BCI Aberthaw 6 4.2 x 65.0 4 1790 2.31 76.1 33.5 1810

Harleyville 1 4.47 x 67.0 4 2008 2.29 79.3 28.3 2410
Bamburi 2 4.2 x 60.0 4 1941 2.71 74.7 30.8 2145
Best month Target
Harleyville 2008 2410
= 2210 stpd = 2655 stpd

ie Harleyville as a preheater kiln would not achieve 3150 stpd peak
Air separate precalciners
Hearth velocity vs Diameter
40
30
Hearthn velocity m/s
20
10
3.25 3.75 4.25 4.75 5.25 5.75 6.25 6.75
Kiln shell diameter
Examples - Air separate precalciners
PROCESS SURFACE AREA HEARTH

PERFORMANCE VELOCITY
t/d/m2
m/s
Air Separate 5.85 38.27

Precalciner (Gujarat) (Tochigi)
31.37
(Lexos)
Examples - Air separate Precalciners
Plant and Type Surface kiln inlet

Kiln Best Hearth target
Area
kiln No of PC Dimensions perfor velocity based on 30
Month perfor- m/s hearth
(m) Dia x L mance mance m/s
tpd velocity
tpd/m2 tpd/m2
Rawang Nº3 NSF 4.7 x 74 5070 5.07 349 29.26 5200

Cauldon ILC 3.95 x 58 3110 4.81 314 29.76 3135
Dunbar PREPOL 4.35 x 3.92 x 60 3190 4.73 260 22.83 4190
Melon 9 ILC 3.6 x 4.9 1900 3.86 236 24.8 2295
Hville PREPOL 4.47 x 67 At least 4600 stpd

Wet process best achieved
Process Surface Area Kiln BE
Tpd/m2 X-section
achieved Achieved
Tpd/m2
Wet & 0.837 110.4

Semi wet (Ravena) (Norman)
Actual and targets - Wet/semi wet
Works & Kiln Dimensions Best Tpd/m2 Tpd/m2 Target
Kiln No Be x bz x L Month Internal Kiln BE based
tpd Surface X -sect On 110
tpd/m2
BCI Northfleet 2 5.6 x 6.0 x 198 2325 0.697 107.8 2370

Masons 5 4.1 x 4.4 x 152 1190 0.645 109.5 1195
Shagamu 2 4.55 x 152 1345 0.679 99.4 1490
Ravena 2 6.1 x 5.3 x 5.6 x 177 2461 0.837 96.4 2805
Semi-Dry process best achieved
Process Surface Kiln BE Grate area
Area X-sect Tpd/m2
Tpd/m2 Tpd/m2 Achieved
Achieved Achieved
Semi-Dry 2.35 156.6 14.75
(Lepol) (Vasiliko) (Vasiliko) (Matera)
Actual and targets - Semi-dry works
Works & Kiln Dimensions Grate Best Tpd/m2 Tpd/m2 Tpd/m2 Target
Kiln No Be x bz x L Size Month Internal Kiln BE Grate based
Wx L tpd Surface X-sect Area On 14.5
tpd/m2
Grate
BCI Cookstown 1 4.35 x 3.92 x 61 3.9 x 27.7 1516 2.16 123.8 13.93 1578
Weardale 1 4.35 x 3.92 x 60 3.9 x 27.7 1085 1.56 88.6 9.97 1578

Mod 3-Process Engineering Objectives

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HBM Process Engineering Conference

Kiln Output Target

3. METHODS USED TO ESTABLISH TARGET OUPTUTS

3.1 Wet and Semi Wet Process

APPENDIX 1 Notes on Hearth Velocity Calculations

- For existing kilns, to quantify the benefits which can be

- For new plants, to enable the sizing of ancillary equipment,

Some examples of output definition are:

I) to iv) are at least related to actual plant performance.

Annual average (t/24h) = Best month (t/24h) x 0.97

Finally, where guarantee figures are relevant

Annual average (t/24h) = Guarantee (t/24h) x 0.93

3.1 Wet and Semi-Wet Process

3.1.1. Assessment of Performance

- Insufficient heat transfer area is available in the burning and

- Results in high gas temperature entering the chain zone

- Results in rapid drying of slurry in the chains

- Causing a longer zone of nodule destruction within the chain

-0 More dust being generated within the chains

3.12. Target Setting

It is concluded that an optimised wet/semi-wet process chained kiln may achieve a

WET KILN PERFUWQ

CETIC Lumbras 4 3.7 x 3.6 x 116 650 0.547 76.0 940

CLOSED M)RKS Norman 1 2.38 x 2.75 x 91.4 MQ. 0.571 110.4

3.2.1 Assessment of Performance

3.2.2. Target Setting

3.3 Suspension Preheater Process

3.3.1. Assessment of Performance

LONG DRY KILN PERF-

Works & Kiln No.

3.75 x 3.45 x 125

* BEFORE CONVERSION TO 2 STAGE PREHEATERS

3.3.2. Target Setting

3.4 Precalciner Process

3.4.1. Air Through Precalciners

SUSPEUSION PREENER KILN PERFoRMME

Works & Kiln No. Kiln Dimensions (m)

l Acutal velocity at 1150 C

AIR TtlROUW PRECALCINER KIIN RATImS

Works & Kiln No. Hearth Velocity

3.5 Semi Drv Process

3.5.1. Assessment of Performance

AIR SEPARATE PRECALCINER KILN RATINGS

Rawang No.3 NSF 4.7 x 74 5070 5.07 349 29.26 5200

3.52. Target Setting

SEMI-DRY OIPOL) KILN f'ERFtHWWX

NOTES ON HEARTH VELOCITY CALCULATIONS

- PREHEATER AND PRECALCINER KILNS

i) Fuel consumption 820 kcal/kg

ii) Back end firing 10% on < 5m diameter kilns

iii) Feed to kiln decarbonation rate

30% at 0% back end firing

iv) Oxygen % at back end

1.3% at 0% back end firing

1) Fuel consumption 820 kcal/kg

i) Fuel consumption 820 kcal/kg

Hearth Area vs. Kiln Diameter1

Output Targets, Performance Benchmarking

OUTPUT TARGETS. PERFORMANCE BENCHMARKING

1.1 Target Setting

2.1 Kiln Tube

1.1 Target setting

This data could then be used to direct performance improvement measures at