Kiln Operation

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TABLE OF CONTENTS

PAGE

GENERAL KILN SECTION

1 Description of Main Kiln System 04

2 Kiln Operation Priorities 05

3 Kiln System Stability 06

4 Main Parameters, Trends and Absolute Values 08

5 Main Parameters to Control and Evaluate Kiln 13

6 Variables which the Operator Cannot Control 15

7 Variables which the Operator Can Control 15

8 Kiln Limitation Factor 16

9 Kiln Operation Target 17

10 Optimization of Kiln System 18

11 List of Most Frequent Factors when Kiln Operation

Is not Satisfactory 19

12 List of Typical Kiln Operation Problems 20

13 What to Look for When Looking Inside a Kiln 21

14 Kiln Upsets 27

15 Kiln Cycling 28

16 How to Break a Cycle in a Kiln 29

KILN EMERGENCY CONDITIONS SECTION

17 Red Spot on Kiln Shell 30

18 Raw Unburned Feed in Clinker Cooler 31

19 Large Ring Broken Loose in Kiln 32

20 Burning Zone Dangerously Hot 33

21 Sudden Sharp Raise in Back End Temperature (B.E.T.) 34

22 Black Smoke Emission from Kiln Stack 35

23 Distorted Flame Shape 36

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24 Loss of Section of Refractory Lining 37

25 Cooler Drive or Clinker Conveyor Stopped 37

26 Red Clinker at Cooler Discharge 38

27 Rapid Rise of Temperature in Coal System 39

28 Power Failure 40

29 A Chain Fire 42

30 Heavy Rain or Thunder Storm 43

31 Sudden High Positive Pressure 43

32 Overheated Kiln Bearing 44

33 Kiln Hazardous Conditions 44

KILN OPERATION SECTION

34 Kiln Operation Techniques 47

35 Burning Zone Evaluation 48

36 Kiln Stable Temperature Profile 49

37 Target Set Point and Operation References 50

38 Back End Temperature Control 51

39 The Three Basic Variables 51

40 Target Range for the Three Variables 51

41 The Three Basic Conditions 52

42 The 27 Conditions (Kurt Peray) 53

43 Kiln Slow Down 56

44 Normal Operation Procedures on Shift 59

45 Plan of Action 59

46 Oxygen Level in Automatic Mode 60

KILN START-UP AND SHUTDOWN PROCEDURES

47 Light-up Flame Example (Gas) 61

48 Preheat or Drying of Refractory Lining 62

49 Heating to Reach Temperature Ready to put Feed On. 63

50 Feed On 64

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51 Kiln Start-up Procedures after a Brick Job 64

52 Example of How to Re-start if Preheat is Required 68

53 Example of How to Re-start if No Preheat is Required 69

54 Kiln Shutdown General Information 70

55 Cooling Procedures 70

56 Kiln Rotation Schedule 71

57 Burner Pipe and Hood Protection 72

58 Emptying the Feed from the Kiln 73

59 Kiln Shutdown Procedures for Brick Job and Red Spot 73

COOLER SECTION

60 Cooler Function 76

61 Cooler Operation 77

62 Cooler Controllers 77

63 Rule on Cooler Operation 78

64 Main Sensors to Control the Cooler Operation 79

65 Particle Size of Clinker 80

66 Operation of Cooler Fans 80

67 Clinker and Air Distribution 81

COMBUSTION SECTION

68 Flame 82

69 Rules on Flame 85

70 Combustion 86

71 Heat Transfer in Rotary Kiln 89

72 Burner Pipes and Nozzles 89

73 Fuels in Cement Industry 92

74 Solid Fuels 94

75 Drying, Grinding and Firing Solid Fuels 96

76 Comparison of the Three Major Fuels 97

77 Combustion Reaction 97

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78 Non-Combustibles (Ash) 98

BASIC PRINCIPLES SECTION

79 Basic Principles, System of Units 98

80 Temperature Scale n/a

81 Some Useful Conversion Factors n/a

82 Basic Principles, Pressure and Flows n/a

83 Basic Principles, Heat and Temperature n/a

84 Basic Principles, Heat Exchange or Transfer n/a

GENERAL KILN SECTION

DESCRIPTION OF MAIN KILN SYSTEMS

Wet Process

Better homogeneity of raw feed

Dust produced is approximately 15 to 20% of clinker production

Dust return to kiln by means of

Vortex at feed location (mixing problem)

Scoop near kiln discharge

Dust insulation in burning zone

Back end temperature is the main parameter to control and react on behavior of slurry through

chain system. (ring formation in chain, spillage near feed end)

High heat consumption (near 1300 kilocalories or 4676 MBtu/st), therefore there is a lower

secondary air temperature.

All other parameters are the same as a dry process kiln.

Long Dry

Feed is dry dust.

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Long residence time (up to 2 hours), so we have to take this into account when stabilizing the

kiln.

Heat consumption is approximately 920 kilocalories (3309 MBtu/st).

Natural load movement often unstable and creates “pushes”.

Pre-calciner and Pre-heater

Residence time in tower is from 2 to 5 seconds.

Residence time in kiln is approximately 30 minutes.

Fast reaction time, requires fast action to control the kiln.

About 50 to 90% calcinations is done in tower.

More stable than long dry, because calcinations is taking place in tower.

Heat consumption nears 800 kilocalories (2878 MBtu/st).

Very high secondary air temperature especially with pre-calciner need tertiary air duct.

Fuel ratio split: kiln = +/- 40%, pre-calciner = +/- 60%

KILN OPERATION PRIORITIES

1. Protection of the personnel working in and around the kiln system is a basic safety rule that

must be strictly followed at all times.

2. Protection of the equipment.

Around the kiln, the safety of the equipment is mainly related to overheating problems and

could be:

a) Back-end of kiln

Do not exceed 840oF (450oC) at precipitator inlet

b) Feed

Do not exceed 10 minutes without feed as the feed end temperature would go

high.

c) Chain inlet temperature

Do not exceed metallurgical maximum temperature of chain system. (usually

approximately 1900oF or 1038oC)

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d) Burning zone

Do not over-heat; keep the raw load near end of flame.

Set a maximum amps level on kiln motor.

e) Cooler

Avoid overloaded cooler grates, cut kiln speed down to protect the cooler

grates.

Avoid high exhaust gas temperature; could damage dust filter system.

Avoid high clinker temperature; could damage the clinker evacuation circuit.

3. Quality.

To produce a well-burned clinker with good free-lime at the desired liter-weight

4. Stability.

Continuous operation should always have priority over maximum production.

Stable kiln operation is the key to long refractory life, high fuel efficiency and uniform

quality clinker.

5. Optimization.

Strive for optimum production level at the lowest possible cost.

KILN SYSTEM STABILITY

1. Stable Feed

a) Chemical

Feed quality range should be:

+/- 0.4% in CaO

+/- 0.4% in SiO2

+/- 0.2% in Al2O3

C3S variations in clinker not to exceed +/- 3%

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Approximately 25% relative potential liquid phase in the clinker is good for kiln burning

and fuel saving.

b) Physical

Good and accurate feed rate indication.

Weigh-feeder should be linear at low, medium and high feed rate.

Good calibration by physical weight of the material should be done at every major kiln

shutdown.

Good feed and speed ratio.

2. Stable Dust Re-introduction to Kiln

Dust collector cleaning cycle sequencing.

Dust circuit configuration should provide stable re-introduction.

Monitoring of the dust return flow is an added advantage.

If dust wasting is required, wasting should be done in such a way not to upset the dust

return to the kiln.

3. Stable Water Spray Injection in Kiln or in Conditioning Tower

Good spray injects into gas stream, not in material load.

Good regulation of water injection with respect to ESP inlet temperature control. (will

cause changes in kiln oxygen level if water flow is not changing smoothly).

4. Good Chain System Design (Wet and Long Dry)

Act as a good dust curtain (dust trap).

Wet kiln design needs to favor a good “plastic zone” in order to prevent ring formation.

Chain tonnage should be between 12 to 14% of clinker production for large kiln and 10

to 12% for small kiln.

Good chains should stand high temperature so that in return enable high production

rates.

5. Good Control of Hood Pressure

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Hood pressure control is critical because it prevents the cooler variations to upset the

burning zone conditions.

Hood pressure set point should be set as close as possible to zero, while remaining

negative.

6. Stable Secondary Air Temperature

The temperature variations during normal operation should not exceed +/- 85oF (29oC)

Good regulation of the cooler under-grate pressure is then required with a thick clinker

bed depth.

The secondary air temperature should be as hot as possible, without damaging the nose

ring or the refractory at the kiln discharge section.

7. Good Production Level

Lower limit:

Under-60% capacity kiln tends to become unstable

Upper limit: Production restriction due to:

Kiln diameter; (maximum flame size, flame erosion on kiln walls).

ID fan capacity; (no leeway on oxygen level)

Precipitator capacity (cooler grates overloaded and high clinker temperature at cooler

outlet)

8. Constant Fuel Quality and Quantity

Constant fuel quality and quantity to allow constant heat input inside the kiln.

MAIN PARAMETERS, TRENDS AND ABSOLUTE VALUES

Back End Temperature

Set point varies with the kiln production level.

Set point varies with the condition of the chain system.

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Absolute value allows one to draw conclusions about efficiency of the kiln system and the kiln

operation.

BET trend is important for the kiln operation.

With the use of water spray in the back end, the water volume will show the reactions of the

back end temperature.

Material Temperature

Slow reaction compared to gas temperature.

In wet process kiln, material temperature is a good indication of the behavior of the material in the

chain system.

Chain Gas Temperature

This temperature is generally a limiting parameter for the kiln operation.

The chain gas temperature set point is generally fixed by the metallurgy of the chain system and

its design.

Absolute value is very important and must be held below the allowed “T” for the chain system.

The trend is representative but has slow reactions with respect to the back end temperature.

Very important to the kiln operation in order to make a good material preparation before it

reached the burning zone.

Burning Zone Temperature

Importance of this instrument is often overestimated.

Precise only when kiln conditions are clear.

The secondary air dust influence in the indication of the instrument and readings are in error

when kiln gets hot and dusty.

It must be correlated with the kiln amps indication and the secondary air temperature to ensure

the validity of the reading.

Shell Temperature (Scanner)

Importance of this instrument is underestimated.

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It is often used only to detect hot spots on the kiln shell, an estimation of brick thickness, and

coating in the kiln.

On bigger charts, it gives a good indication of the burning zone temperature profile.

It is one of the fastest indications of a slowly moving ignition point in burning zone.

It is a very good indication of flame variations due to the burner pipe position, flame shape and

direction. (Good indication when adjusting flame in kiln).

Absolute value is important to detect hot spots and rings.

Trend indicates changes in the burner system, kiln speed, ignition point movement and

operating conditions which are affecting the temperature profile of the burning zone.

Kiln Drive Amps

It is the most important sensor used to evaluate the burning zone state.

The running set point will change according to the raw material composition.

Amperage value changes with ring formation.

Amperage value changes with the size of the clinker.

The absolute value is important only when amperage is high (fuse protection limitations).

The trend is a very good indication of burning zone length and temperature; therefore the amps

should be recorded in such a way to give a good indication in its variations.

A drastic increase of the amps trend, followed by a fast decrease is an indication of loss of

coating or a broken ring inside the kiln.

A target amps range should be established (depending on raw mix and other factors) through

which this variable can fluctuate safely.

A drastic increase in amps could indicate a possible mechanical condition problem.

NOx Analyzer

Essentially it is an indication of the flame temperature. Higher is the flame temperature, the

higher will be the NOx concentration.

NOx content in the flue gases in the smoke stack originate partly from high temperature

synthesis in flame from oxygen and nitrogen.

NOx level has been measured in the range between 500 and 2000 ppm in the Lafarge group.

NOx increase with excess air and is strongly correlated to low excess air levels.

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At higher levels, i.e. 3% and greater, NOx is weakly dependent on excess air.

Correlation between burning zone temperature and NOx level is good.

NOx is generally, but not systematically correlated with the kiln drive amps. NOx gives a truer

picture of burning conditions. Kiln drive amps will change due to ring formation and

degradation, whereas NOx signal will not.

NOx correlates better with clinker liter weight than free lime.

NOx is affected by fuel changes. Natural gas flames yield the highest NOx level.

All the factors having an impact on the flame temperature will affect the NOx signal like the

following:

The secondary air temperature,

The primary air temperature,

The burning zone temperature,

Chemical composition and fineness of the fuel,

The air and fuel ratio and

The flame environment (reduced or oxidized atmosphere).

A quick decrease in the NOx signal is an indication of the burning zone temperature dropping.

A slow and even decrease on the NOx signal is an indication of a slow cooling of the burning

zone and is related to a bad material preparation from the kiln back end.

On the automatic kiln control system developed by Lafarge, the program is giving 30% of it as

evaluation of the burning zone state to the NOx signal, 55% to the kiln amps, and 15% to the

clinker temperature at the kiln outlet.

Secondary Air Temperature

It should be kept as stable as possible by the automatic cooler control system (+/- 85oF or 39oC).

Absolute value is not important because most indications are incorrect due to instrument

inaccuracy.

Trend is very important as it shows variations of material from the kiln and the gas temperature

variations to the kiln.

The secondary air temperature should be as high as possible in respect of the various refractory

temperatures in front of the kiln.

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Hood Draft

Absolute value is important and is automatically controlled at a constant value (usually looped

to cooler exhaust fan damper / fan).

It should be low as possible (to reduce in-leakage).

It is the separation between cooler and kiln and it should be always constant to avoid influences

of changes in the cooler gas flow to the kiln operation.

A poor regulation of this signal will induce variations in the kiln gas flow and could bring the kiln

into cycling.

Feed End Draft and ID Fan Draft

Trend and absolute value help to detect build-up in the kiln.

This is a very important sensor if many ring problems occur in a plant.

Cooler Exhaust Gas Temperature

Trend will give you information about the temperature profile in cooler gas flow variations and

clinker temperature.

Absolute value is an important limitation for protection of the dust collection system.

The cooler exhaust temperature is a more reliable clinker discharge indication than the clinker

temperature.

Clinker Discharge Temperature

Trend has no importance for cooler operation.

Absolute value is an important limitation for safety of the clinker transport system.

Clinker temperature measurements are generally not very accurate.

Under Grate Pressure

The absolute value should be maintained constant with automatic control.

The value varies with the cooler bed depth and with clinker size. It must be held constant in

order to achieve a constant secondary air temperature. Also, only a constant air flow can allow

the relationship between under grate pressure, bed depth and secondary air temperature to be

valid.

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Variations of the under grate pressures trend are reflected by variations in the cooler grate

speed.

Under grate pressures together with cooler drive amps, should give an indication of the clinker

size.

Under grate pressure set point should be at least 5 inches (H2O) in order to get good heat

recuperation from the clinker bed in the cooler.

Oxygen Analyzer

Trend and set point value are very important.

It should be maintained as constant as possible.

It can supply indications about general kiln conditions, burning zone and back end temperature.

One of the best indications when the kiln is pushing to indicate if the push is still on or over

(related with the amount of CaO in the kiln gases).

It should be kept as low as possible when the kiln is stable, without going into CO range.

However, when using coal or coke, set point should be increased to overcome the fuel quality

variations.

MAIN PARAMETERS USED TO CONTROL AND EVALUATE KILN

Kiln Amps

It is a very good indication of the burning zone state, accurate at 80% of the time.

NOx Analyzer

Nitrogen Oxide level is related to the flame temperature than the burning zone temperature.

NOx vary all the factors that has an effect on the flame.

It is a very good indication of the burning zone state.

Fuel Flow

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It should be related to the kiln feed rate.

It should be used as the main controller for the burning zone and the kiln back end temperature.

Kiln Speed

It should be related to feed rate.

It should be set with a constant feed ratio.

Small variations of the kiln speed (1 to 3 revs) could be used to control the burning zone state.

However, kiln speed variations should be used only after the fuel flow rate has been used as the

primary controller on long wet and dry kiln.

Often if over used, speed variations in the material loading of the kiln and will lead the kiln into

a cycle.

On large temperature variations in burning zone like raw material pushes, the kiln speed must

be used with wide variations (as example 30 revs or even a complete stop) to avoid raw

materials to go in the cooler and to re-heat the burning zone.

Fan Draft

It should be related to the oxygen level, fuel flow rate and feed rate.

It is the main controller to keep the temperature profile along the kiln.

The rpm variations should be small during kiln normal operation +/- 15 rph.

During kiln pushes and kiln slow speed, large speed variations will be required to maintain the

chain gas temperature under safe limit of the chain system.

Back End Temperature

It should be kept at constant level according to feed rate.

It should be kept stable in auto by the water spray system.

Good indication of the feed end “T”.

Indicate variations in the feed and dust variations to the kiln.

When in auto, use water flow variations for indication.

Gas Temperature

It is the main variable to control the kiln.

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It should be kept inside a certain “T” range.

It is controlled by the ID fan speed variations and the fuel rate.

Oxygen level

It is related to the ID fan speed and fuel rate.

Minimum and maximum level limits need to be established, to control combustion efficiency.

When kiln stability has been reached the O2 level should be set in auto with the ID fan speed to

lock the temperature profile of the kiln.

Hood Pressure

Control of excess air by cooler exhaust fan

Open during kiln pushes

Need to be kept stable to avoid variations in cooler to upset the burning zone

Secondary Air Temperature

Temperature of combustion carried back to kiln from the cooler

Large variations during kiln pushes

Should be controlled in a very small range in auto during normal kiln operation with a good

regulation of the clinker cooler (+/- 85oF or 39oC)

Cooler Exhaust Temperature

Varies with clinker input to cooler

Will indicate variations during a push

Under Grate Pressure

Related to cooler grate speed

Set point controlled by the under grate pressure of second compartment to keep a constant clinker bed

depth in order to get stable and high secondary air temperature

VARIABLES WHICH THE OPERATOR CANNOT CONTROL

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Quality and characteristics of the raw materials

Quality of the fuel used as a example: heat value, ash content, volatile matter and moisture level

Dust quality and quantity returned to the kiln

Accuracy of the feeders

Chain system design

Accuracy and good response of all control loops and sensors of the kiln system

For these variables that he cannot control, the operator should be kept informed of any changes done

and should make sure that those variables are kept inside an acceptable range to maintain a good kiln

stabilization.

VARIABLES WHICH THE OPERATOR CAN CONTROL

Material feed to the kiln

Fuel feed to the kiln

Speed rotation of the kiln

Temperature profile along the kiln

Draft at the feed end of the kiln

Supply of combustion air

Retention time of the material in the kiln

Temperature of the combustion air

Flame shape

Observation of instruments, and correct reaction to their readings

Observation of the kiln burning zone, and correct reaction to this evaluation

However, some restrictions are sometimes given on the utilization of those variables and may vary from

plant to plant due to local conditions and are usually the following:

Set point on the maximum speed of the kiln

Set point on the maximum feed rate to the kiln

Automatic loop set point for oxygen level and ID fan speed

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Settings on the burner pipe and its position

Primary air settings and fuel tip velocity

Set point on cooler fans flow

Set point for the under grate pressure and the clinker bed depth in the cooler

KILN LIMITATION FACTORS

Dust Emission at Precipitator Stack (Local emission regulations)

Gas Chain Temperature

Maximum value depend on chain quality and position

Diameter of Kiln

Gas velocity in kiln (70 ft/sec in free section of kiln and 30 ft/sec in chain section maximum)

Heat load in front of kiln, flame erosion on kiln walls

ID Fan Capacity

Maximum fan speed and low oxygen level

Cooler Capacity

No red clinker should be present after third compartment of cooler in normal operation

Clinker discharge temperature not to exceed 170oF (80oC)

Cooler exit gas should be about 370oF (190oC)

Bed depth to allow good under grate pressure (15”) with sufficient fan capacity

KILN OPERATION TARGET

Highest clinker production with

Good quality clinker

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Stable kiln operation

Oxygen level as low as possible

Gas and fuel oil – 1.0 to 1.5%

Coal and coke around – 2.0% (depending on the variations in fuel mixture)

Kiln exit temperature as low as possible

Flame as short as possible (with respect of the burning zone refractory)

Keep burning zone short in front of the kiln

Secondary air temperature as high as possible but stable

Temperature not above liquid phase temperature in front of kiln to protect refractory and

coating

Run with an under grate pressure as high as possible

Compatible with the cooler fans static pressure capacity

Primary air as low as possible

As combustion air to replace by hot air from cooler as much as possible

Clinker Temperature

Not to exceed 230oF (110oC) as it could promote quality problems (false set) during the grinding process

Gravel bed filter

Normal operation temperature is 350oF (180oC)

Maximum temperature for normal operation is 660oF (350oC)

For 2 hours, up to 750oF (400oC)

For 20 minutes, up to 840oF (450oC)

OPTIMAZATION OF THE KILN SYSTEM

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Operate the kiln:

With higher free lime

Reduce air leakages:

Around and near the nose ring area and seal

Air in-leakage on kiln hood

Around blast pipe port holes and doors

Hood pressure set point as close as possible to zero

Primary air should be kept as low as possible

Reduce length of pre-cooling zone by:

Adjusting the burner position

Proper material load (kiln speed/feed ratio)

Increase clinker bed depth in cooler (near 15 inches)

Oxygen to be maintained at minimum level

Good flame shape and temperature

Good chemical composition

Good burnability factors

Constant raw mix

TYPICAL KILN PROBLEMS

List of most frequent factors at work when kiln operation is unsatisfactory

1) High leakage, pre-heater only into feed end seal (more than 5%)

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2) Faulty suspension results in high pre-heater outlet temperatures, thus reduces capacity (bleed

air)

3) Poor operating practices (burning techniques)

4) Reducing conditions in kiln

5) Reducing conditions in burning zone due to flame impingement with load

6) Lack of momentum at burner tip leads to long, lazy flame

7) High primary air, (30%+) due to direct firing of coal, (critical in dry process kiln)

8) High level of volatile elements in raw feed particularly chlorine

9) Systematically hot burning

10) Inadequate chain system

11) Poor cooler heat recovery due to cooler fan design

12) Poor cooler heat recovery due to excessive air flows, insufficient pressure in under grate

compartments

13) Chemically variable raw mix C3S, more than 10 points over a shift

14) Variable slurry moisture (more than 3 points)

15) Variable addition of hi-alkali or hi-volatile dust from precipitator (over a period of more than

one-half hour)

16) Erratic feed rate

17) Erratic fuel rate (wet coal)

18) High leakage into hood seal (more than 10% of combustion air)

19) Inadequate or obsolete design of equipment or facilities

20) High leakage into pre-heater and down-comer duct

21) Flame erosion on lining could create premature brick failure

22) Kiln misalignment, excessive tire clearances and other factors of shell deflection

23) Bricking techniques lead to rings not tight enough

24) Low slurry moisture

25) High slurry moisture

List of Typical Kiln Operating Problems

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1) Heat consumption higher than normal

Long dry: Higher than 3.4 MBtu/ton

Long wet: Higher than 5.2 MBtu/ton

Four stage Pre-heater: Higher than 3.1 MBtu/ton

2) Output lower than nominal and / or standard

3) Kiln is unstable and requires frequent massive shutdowns

4) Kiln is cycling spontaneously without any action of operator

5) Kiln is out of draft with output below nominal

6) Stack stinks – SO2 emissions are high

7) Mud ring in chain section on wet kiln

8) Back-spills on wet kiln

9) Burning zone rings

10) Discharge end rings

11) Snowmen in cooler

12) Frequent burning zone burnouts (brick life is less than 3 months)

13) High dust return (above 20% of clinker) causes handling problems

14) Cyclones plug-ups (four stage pre-heater)

15) Build-ups in pre-heater feed box (four stage pre-heater)

16) Cooler exhaust system seems undersized/under-designed

- Hood frequently under pressure (during pushes)

- Exhaust temperature is higher than normal

- Bleed in damper is open very often

- Frequent bag burnouts in cooler bag house

17) Red grates in the cooler all the time. Frequent grates burnouts

18) Red rivers on side of cooler

19) Under pushes, cooler speed up to maximum, yet some fans stop blowing any air (pressure

overload)

20) Kiln drive seems undersized, kicks out upon start-up after a short shutdown

WHAT TO LOOK FOR WHEN LOOKING INSIDE A KILN

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Viewing the kiln interior

This may sound somewhat elementary, but we should never forget that we are looking into an

extremely luminous source. Although filtering glasses are used, the light source is so strong that focusing

the eyes into it for too long a time could cause partial blindness. One should look no longer than one

minute at a time into the fire. If longer viewing is required, look a side for few seconds occasionally to

rest the eyes. Looking steadily too long at the flame results in the eye losing its ability to see details,

hence the need for a short rest every minute or so.

The question of what type of colored filter glass to use must be left to the operators. Burning

with a natural gas flame usually makes necessary a darker colored than oil fire would require, because of

the greater luminosity of the flame. As a rule, one should always use a glass that enables him to see

under and behind the flame. Once a certain glass has been chosen, the operators should stay with this

glass at all times in order to properly judge the burning zone conditions. How frequently should one look

into the burning zone? There is no set answer to this question. Experienced operators sometimes

become over-confident and think that it would be perfectly safe to leave the kiln alone for periods in

excess of 30 minutes. This action however, is against good burning practice. The secret of every good

operator is his ability to recognize a change in kiln condition at the time a change takes place and not

later. For this reason, a good operator will never leave a kiln too long a time unchecked. When things

are going smoothly, the kiln should be checked every half hour, with more frequent checks if

adjustments are being made. There is no such thing as operating a kiln by the instrument alone, as the

instruments do not show, for example heavier and lighter loads entering the burning zone until it is

almost too late to make the necessary adjustment.

The kiln condition can be estimated from the color observed in the hottest part of the flame.

Dark red cherry red orange-yellow white

Cold - - normal hot

Any deviations from the orange-yellow range should be investigated to determine the cause and when

adjustments need to be made to the kiln operation to get back to normal kiln condition.

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Appearance of burning zone

Good or bad visibility

Bright white or dark red color

Good appearance is an orange-yellow color

The gas stream should be calm without great turbulence

Appearance of coating

Coating should begin approximately ½ diameter of kiln size from the nose ring

Color of coating tells a great deal about the condition in burning zone as coating acts as heat

storage in burning zone

Overall thickness of coating should be between 9 and 12 inches and is dependent of the type of

raw mix

Check for ring formation near lower or upper section of the kiln

If the surface of the coating appears smooth, then the burning zone in this area is hot

If the coating appears “lumpy” then the burning zone is okay

A bare spot without coating could be due to flame erosion, thick brick or high flame

temperature in this location

Appearance of the coating falling off from the top of the kiln shell:

Large pieces: normal

Fine noodles dripping: too hot

The location where the coating pieces are falling from the top of the kiln wall, above the end of the

flame is generally where the raw load is. So whenever the raw load cannot be seen in the bottom and

behind the flame of the kiln, try to look at the top.

Appearance of material load

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Is clinker balling or fine?

Is material sticky?

Is material heavy or light?

Is material movement fast or slow?

Is material climbing low or high in the wall? (material should climb up +/- to the 10 o’clock

position in normal operation)

Appearance of material before falling in the cooler, fine or nodular

Upper burning zone section

Are rings building up or not?

Is coating formation seem normal?

Try to evaluate the length of the coating (50 to 100 feet from burning zone to far up)

Raw feed location

Look behind the flame at the bottom of the kiln

Normal position is approximately ¼ diameter distance under the flame

Never allow raw feed to come ½ way under the flame as kiln speed will have to be reduced to

control it (kiln low speed)

An advancing or receding dark feed is the earliest indication of a burning zone that is warming up or

cooling down. So that is why it is important for the kiln operation to be able to see this load. Every effort

should be done during normal operation to keep this load in sight.

Flame appearance

Should always be evaluated during stable kiln condition

Long (100 ft) or short (30 ft)

Hard or lazy

Bushy or narrow

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Bright or dark

White or orange yellow

Eroding the coating or the brick wall

Aiming high, low or in the center

Eroding the material load

If fuel is burning in suspension or in the material load

Position of the ignition point when coal or coke is used

The flame temperature should be as hot as possible as long as it does not create problems with the

coating and the kiln refractory. Whenever a change is made on the flame shape, a close monitoring of

the shell temperature should be done.

Coal flames

Coal normally burns with longer flame than oil

A coal flame normally starts at 3 to 5 feet from the burner tip

Coal fineness to be about 85% passing 200 mesh

Keep the coal system air flow at about 70 ft/sec to avoid coal deposit inside pipe, while keeping

primary air to minimum (direct system and burner design)

On direct firing system, coal fan damper setting should be set at minimum value and the fuel rate

changes made only by making changes with the coal feeder system in order to keep the flame shape

short and as constant as possible.

Burner pipe appearance

Is the tip of the blast pipe in good condition?

Is the burner cast-able in good condition?

Is the burner pipe aimed correctly?

How is the pipe location relative to the nose ring?

Are snowmen building up on top of burner pipe?

Whenever a bad condition deflecting the flame is observe, a quick evaluation should be done to

evaluate if the kiln can continue its operation or if it needs to be shut down to fix the burner pipe.

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Nose ring appearance

Check the condition of the cast-able or the refractory on the top of the nose ring if okay

Check the temperature aspect and the wear of the nose ring castings

Check if the nose ring seal is in good condition

Secondary air

Calm or upset

Dusty if the clinker is fine

Clear if clinker is balling

Foggy and white if temperature is hot

The secondary air temperature has a major influence on the flame and its shape.

Primary air

Should be as low as possible to obtain satisfactory heat recuperation from cooler

Has an important influence on the shape of the flame (bushy or narrow)

Pressure should be as constant as possible

When good settings of the flame have been found, the primary air settings should not be changed in

normal operation unless a high temperature condition in the kiln refractory has raised and required to

change the flame.

When the kiln is down

Look for ball or ring formation at upper section of burning zone

Evaluate length of coating if okay, too long means we burned the kiln too far up

Load level inside kiln if even and normal

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Appearance on load during kiln jacking (sticky or normal)

Look at the sealing efficiency of the kiln back end (no suction or gases movement inside of kiln should be

observed).

When kiln is shutdown, the gases should be bottled inside of the kiln as fast as possible by closing the

kiln back end damper or its equivalent and by adjusting the hood pressure set point, slightly positive.

The procedure need to be done to avoid heat loss from the kiln to insure a slow cooling of the refractory

and avoid thermal shocks on the bricks.

KILN UPSETS

Burning zone too hot

Too much liquid is formed and all temperatures are above the solid state temperature therefore no

coating is formed. Coating will be lost and this could damage the refractory.

A) Appearance the kiln could be white and hazy in front end and the clinker will be balling.

B) Appearance of the kiln could appear cold if burning is too far. The clinker could be fine (very

long burning zone).

A) Hot burning zone with high secondary air temperature

The front of kiln is very hot and white, often hazy

The secondary air temperature is high

The clinker is balling and getting bigger

Often the dark load is visible behind the flame

These conditions occurs when the burning zone length is moving down and concentrating the

heat on a shorter burning zone length in front of kiln.

This situation can be overcome quite easily by reducing the fuel rate and the ID fan slowly step

by step until the burning zone gets back to its normal condition.

B) Hot burning zone with dusty secondary air

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Can be caused by burning too far back into the kiln

Flame too long and ignite too far

Pre-cooling zone is too long in front of the kiln

Long burning zone promotes very fine clinker formation which is sent back as dust into the

kiln with the secondary air gas stream

Whenever dusty conditions prevail in front, corrective measures should be based on the

clinkering conditions behind the flame rather than on the color of the front of the kiln.

Aspect of the clinker falling in cooler is very important at that time to evaluate the kiln

condition.

Kiln amps, fuel flow rate, shell temperature and back-end temperature are usually

above the normal operation settings during these conditions.

Get free lime done from clinker coming out of the kiln to see if OK

If operator is in doubt about the kiln being cold or hot, the kiln rotation could be

stopped (out of the interlock for a few seconds) to allow condition of the burning zone

to clear and to view inside the kiln

If doubt still persists, the kiln should be assumed to be hot and it should be cooled down

by reducing the fuel and the ID fan speed until the burning zone get back normal or end

up to be completely cold.

Except for very hot and emergency conditions, such as cooling should take as long as a

full shift to be done, to avoid high heat concentration in front and quick losses of

coating from the upper section of the burning zone which could upset the burning zone

temperature.

KILN CYCLING

This is an unstable condition when the load in the kiln decreases, causing the temperature of the

burning zone to rise and forcing the operator to reduce the fuel rate. Then, the burning zone starts to

cool off in turn forcing the operator to increase the fuel rate. In severe cases, the temperature continue

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to drop, even though the fuel rate is at maximum and it become necessary to reduce the kiln speed to

slow down the entry of the feed into the burning zone. Once a kiln gets into an upset such as this, the

cycle will repeat.

Kiln cycling could be related to the following reasons;

Variations in kiln feed: physical or chemical,

Variations in dust re-introduction to kiln,

Variations in the water spray control system in kiln inlet (if any),

Materials hold up in the chain system (for wet process kilns),

Poor chain system design (for wet process kilns),

Variations in hood pressure control

Poor cooler settings and control which promote secondary air temperature variations,

Operating the kiln above its production capacity,

Variations in the quality and the quantity of the fuel supply to the kiln,

Bad operating practices, especially over reacting with the kiln speed and

Volatile recirculation inside the kiln system especially chlorine

So all the above reasons should be investigated in order to find the cause of the cycling problem and

corrected.

HOW TO BREAK A CYCLE IN A KILN

Reduce feed/speed ratio by approximately 10% in order to change the material load in the kiln

(also mainly to change the material load in the chain system).

Increase the fuel flow rate by 5% above the normal setting of the current production level.

Keep the oxygen level above 2% and try to control the back end temperature variations as much

as possible by using fuel rate and ID fan variations.

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Let the kiln amps vary and do not attempt to chase them by varying the kiln speed. Just try to

control them if they get above or below the critical range by varying the fuel flow rate.

If the kiln speed need to be varied than it should be done with very small variations, in order to

avoid upsetting the material in the kiln.

If the kiln speed needs to be increased to go back to normal production level, then it should be

carried out more slowly than normal.

As you get to normal production level, fuel settings should be held above normal before returning to

normal operation settings.

KILN EMERGENCY CONDITIONS SECTION

RED SPOT ON KILN SHELL

Indicators:

By visual observations

Shell scanner sharp and rapid shell temperature increase to level above 850oF (450oC)

Visual observations of loose refractory bricks in the material load of the kiln or in the clinker at

the cooler discharge

Possible Effects and Danger

Severe warping and damage to kiln shell

Shell temperature between 900 and 1100oF (480 and 590oC), deep red color on shell

Shell temperature over 1200oF (650oC), very bright red and shell bulges and warps

Recommended Actions to Take

A) For small red spot located in the upper transition or center of burning zone

Continue normal operation of kiln but:

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Place shell cooling fans in the area of red spot

Shorten flame to bring black feed over area of red spot in attempt to form new coating

Keep watching the shell temperature trend

Maintain normal burning zone temperature

Change kiln feed chemistry to obtain an easier burning mix

B) For large red spot located under or near a kiln tire or in areas were no coating is formed

SHUT DOWN KILN IMMEDIATELY

Warning: Under no circumstances should a water spray be used on the red spot, as this

could result in severe kiln shell damage.

Possible Measures to Prevent Re-occurrence

Make sure flame configuration and characteristics are not causing localized coating erosion or

continuous and excessive overheating

Employ proper refractory installation methods

Minimize frequency of kiln shutdowns and upsets

Minimize frequency of clinker type changes over

Avoid “hard” burning mixes (i.e. ensure sufficient percentage of liquid content in mix to

promote coating formation)

RAW, UNBURNED FEED IN CLINKER COOLER

Indicators:

On rush of raw feed into and beyond burning zone

“Black feed” position advanced more than ½ way under the flame

“Black-out” in burning zone

Red grates in cooler

Rapid rise in cooler grate and clinker discharge temperatures

Cooler drag-chain amperage increases rapidly

Possible Effects and Danger

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Thermal damage to cooler grates and grate drive mechanism

Fire on clinker conveyor belts

Excessive high temperatures in coal mill air circuit

Warning: Watch for incomplete combustion when visibility in burning zone is severely restricted.

Actions to Take

First and foremost, do not wait until raw feed is in the cooler; act when the first signs of impending

problems are visible in the burning zone.

Immediately reduce kiln speed to minimum (or turn on auxiliary drive)

Reduce fuel and ID fan speed in accordance with standard slowdown procedures to protect the

kiln back end temperature

Reduce cooler grate drive speed (switch to manual control) to allow material in cooler more

time for cooling

Adjust cooler air flow rates to obtain maximum cooling without the hood pressure going positive

Advise all unauthorized personnel to stay clear of the firing floor, cooler and coal mill area

Preventive Measures to Avoid Re-occurrence

Accelerate frequency of visual observations of burning zone for early detection of impending

cooler upsets

Evaluate kiln output rates vs. capabilities and kiln operating stability

LARGE RING BROKEN LOOSE IN KILN

Indicators

Visual observations of large junks in burning zone

Sudden drop in kiln back end draft

Large drop in oxygen content of kiln exit gases

Hood pressure tending towards positive side

Sudden change in kiln drive amperage

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Possible Effects and Dangers

Overloading cooler with unburned feed

On rush of excessive amounts of feed into the burning zone

Damage to cooler drives and grates

Large pieces jamming cooler hammer crusher

Red hot clinker leaving cooler

Actions to Take

When amount of feed and ring fragments in burning zone are extremely large:

Immediately reduce kiln speed to minimum

Reduce fuel and ID fan speed to keep back end temperature under control

Switch cooler grate control to manual and reduce grate speed

Adjust cooler air flows to maximum flow possible, without the hood pressure going positive

Have personnel on standby to watch the cooler and the hammer crusher for possible

overloading, overheating and jamming

Possible Preventive Measures to Avoid Re-occurrence

Laboratory to reevaluate chemistry of kiln feed (including dust return rates) for possible

elimination of ring formation if no solution in this area possible, then

Initiate regular schedule to remove rings and heavy build-up by means of special devices design

for this purpose

Initiate regular procedures to displace the burning zone location on a daily basis

BURNING ZONE DANGEROUSLY HOT

Indicators

Clinker balling in burning zone

Material load sausage-like

Coating dripping off the wall

Sliding molten clinker bed in burning zone

Burning zone recording temperature too high

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Cooler under grate pressure too high

Material load turning to liquid in burning zone

Very brilliant and white burning zone


Loss of coating and thermal damage to refractory

Red spot in the kiln shell

Thermal damage to cooler and kiln hood components

Possible Actions

Reduce fuel flow rate to minimum until sausaging stops

Increase kiln speed approximately 10 rph until sausage is broken

Provide maximum air in cooler (without hood pressure going positive)

The kiln rotation to be adapted is the aspect of the material near to fall into the cooler. No liquid

material in the cooler, stop kiln rotation if needed.

Reduced primary air flow, then as soon as the objective of breaking the agglomeration is

accomplished,

Reduced the kiln and ID fan speed then increase fuel flow rate to normal operating conditions

Preventive Measures

If “sausaging” is frequent and result of easy-burning mix, have laboratory evaluate possibility of

providing a mix with less percentage of liquid content

Make more frequent, vigilant observation of the burning zone conditions

Evaluate flame position and shape to determine if thinner, longer flame is possible

SUDDEN, SHARP RAISE IN BACK-END TEMPERATURE

Possible Reasons

Feed shortage

Combustion in exit gas

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ID fan speed too high

Kiln speed too low

Chain fire


Chain fire on wet and dry kilns

Thermal damage to back end, dust collector and pre-heater tower equipment

Delayed ignition of fuel in back end of kiln

Possible Actions

Immediately de-energize electrostatic precipitator

Immediately reduce fuel flow rate and ID fan speed to obtain less than 0.3% oxygen in exit gas

Warning: Do not cut off fuel flow rate completely as this could trigger an explosion.

Increase kiln speed and feed rate

Warn personnel to stay clear of kiln back-end

Do not open any doors in kiln back-end

Then as soon as the primary objective of bringing the kiln back-end temperature under control is

accomplished:

Return kiln control variables to normal to restore operating conditions

Check out back-end to determine if thermal damage had occurred

Preventive Measures

Do not operate kiln without feed for more than 10 minutes

Provide alarms and properly maintain kiln instrumentation to obtain warnings before the back-

end temperature gets out of maximum range

Maintain close vigilance over combustion, back-end and flow conditions during kiln starts,

shutdowns and upsets

BLACK SMOKE EMMISION FROM KILN STACK

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Indicators

Combustibles in exit gases

Oxygen in exit gas too low

Flame extinguished for poor ignition conditions

Burning zone temperature too low

Excessive fuel rates and/or insufficient kiln draft

Possible Actions

Immediately de-energize electrostatic precipitator

Immediately reduce fuel flow rate (do not shut off)

Increase ID fan speed to obtain:

a) Zero combustible in exit gas

b) Oxygen between 0.2 and a maximum of 0.5% in exit gas

After black smoke has cleared, maintain the low oxygen/zero combustibles for at least 10

minutes before restoring kiln variables to normal

Preventive Measures

Improve control over flame and firing conditions

Make frequent, vigilant observation of fuel flow rates, gas analysis, flame and kiln draft

conditions during kiln starts and upsets

DISTORTED FLAME SHAPE

Indicators

Irregular and unusual flame shape

Fragmented flame where part of flame impinges on lining near kiln discharge area


Inspect burner pipe for damage or plugged circuit

If flame is erratic and severely impinges upon lining near the kiln discharge area:

Shutdown kiln immediately!

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If flame is only slightly distorted; adjust burner position and primary air flow

Check shell temperature on kiln scanner

Schedule a burner pipe repairs for next kiln shutdown

Preventive Measures

Frequent visual inspection when looking inside the kiln

Regular inspection and maintenance of burner pipe during each prolonged kiln shutdown

Improve protection (castables, air cooling) for burner pipe

Maintain primary air flow for at least 2 hours after a kiln has been shutdown or pull back the

burner pipe immediately when kiln is being shutdown

LOSS OF SECTION OF REFRACTORY LINING

Indicators

Loose bricks in clinker bed of burning zone

Delineated (linear instead of round) red spot on kiln shell

Rapid rise in kiln shell temperature


Thermal damage and distortion of kiln shell and tire

Further collapse of large sections of linings (especially in alumina brick sections)

Possible Actions

Immediately shutdown the kiln

Preventive Measures

Employ proper refractory installation methods and procedures

Make annual checks of kiln alignment and shell ovality

Have refractory manufacturer provide uniform shapes and proper expansion allowance for each

type of brick

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Avoid excessive turning when kiln is cold during shutdowns

COOLER DRIVES OR CLINKER BELT STOPPED

Indicators

Cooler overloaded

Large chunks of coating in cooler

High under grate pressure

High cooler drive amps prior to drive stop

Clinker transfer chutes plugged


Thermal damage to cooler components

Possible Actions

Immediately reduce kiln speed to minimum and attempt to restart clinker belt and/or cooler

drive

If drives cannot be restarted within 5 minutes, shutdown the kiln

Note: After kiln has been shutdown, consider possibility of turning the kiln in less frequent intervals

to prevent further overloading of cooler. (Kiln still had to be rotated periodically nevertheless)

Preventive Measures

Know at what amperage the cooler drive is likely to fail and provide alarm for overload

Adjust kiln parameters (namely kiln speed) before cooler can become overloaded at the times

when heavier feed load is observed in the burning zone

RED CLINKER AT COOLER DISCHARGE

Indicators

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High drag chain amps

Sudden drop in under grate pressure (grate out)

Excessively high under grate pressure (cooler overloaded)

Cooler drive amps and clinker bed depth too high

Cooler loaded with coating and ring fragments

Snowman formation at cooler inlet


Thermal damage to cooler components

Thermal damage to clinker transport equipment

Possible Actions

Immediately make a visual check of the cooler to determine reason for red-clinker discharge

If cooler grate out, shutdown kiln

If cooler overloaded, reduce kiln speed to minimum and reduce cooler grate drive speed to

allow more time for cooling

Increase air flow into cooler

Activate water spray at cooler discharge and reroute clinker to prevent damage to conveyor

belts

Preventive Measures

a) On frequent grate failures

Investigate for possible faulty grate installation methods by maintenance department

Investigate quality of grates and bolts used

b) On frequent one-sided loading of cooler bed

Investigate possible cooler design changes

Investigate possibilities for elimination of stalagmite (snowmen) formation at cooler

inlet

c) On frequent overloading of cooler due to upsets

Slow down kiln speed before raw feed enters cooler or cooler can become overloaded

(make your corrective moves before things get out of control)

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RAPID RAISE OF TEMPERATURE IN COAL SYSTEM


Explosion

Thermal damage to coal system

Possible Actions

Warning: Do not open any door in the system that could provide the oxygen for an explosion or

a more serious fire.

Inject inert gas (CO2) into coal mill inlet

Flood coal mill with kiln feed or excessive coal

Warn all personnel to stay clear of system

Stop or reduce air flow to coal mill to minimum

Preventive Measures for Re-occurrence

Provide coal mill inlet with magnetic device to extract metal fragments from coal feeder belt

Keep paper, rags, etc. out of coal storage pile

Do not feed coal mill with coal that has undergone spontaneous ignition (smothering) while in

storage

Keep coal mill de-tramp chute clear

Provide coal mill system with automatic fire-extinguishing devices

Do not operate coal mill above predetermined safe temperature for any given type of coal

POWER FAILURE


Warping of kiln shell

Thermal damage to burner pipe, instrumentation and equipment at kiln discharge area

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On coal-fired kilns, settlement of ground coal in coal system that could lead to a fire and/or

explosion

Possible Actions

Immediately start auxiliary power generator and primary air fan (coal mill fan on direct fired

kilns)

Retract burner pipe and protect TV monitor in kiln hood

Start ¼ turn on kiln not later than 10 minutes after the power failure

If available, close feed-end damper manually to prevent hot gases from escaping from kiln by

natural draft

Power Failure Main Procedures

Start generator or auxiliary drive

If it is raining, carry out ¼ turn as described previously

Close kiln back-end, ID fan damper, or precipitator inlet damper if power failure is of long

duration

Keep primary air fan running to cool down the burner pipe (and pre-calciner burners) or pull the

burners out of the kiln

Try to restore power as soon as possible

The following should be connected on the auxiliary power system:

Emergency light in control room

Emergency light in kiln platform

Telephone system for outside calls

Radio system inside the plant

ID fan louvers and precipitator inlet damper

Kiln auxiliary drive

Primary air fan

Recirculation pump for the industrial water system (water cooling system)

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Instructions should be given to all members of the shift for specific responsibilities during a power

failure as example:

Operator A:

Carry out safety procedures on kiln system

Start the auxiliary power system

Close kiln back end (if on auxiliary system)

Rotate the kiln

If it is raining continuously, rotate kiln as soon as possible

Protection of burner pipe (pull out of kiln

Call the power company

Operator B:

Get to main power breaker and try to reset it

Go to kiln back-end and close ID fan louvers (if they are not connected on the auxiliary drive)

If the auxiliary drive control is not remote, make kiln rotation in local

A CHAIN FIRE

Indicators

Rapid, sudden rise in intermediate and exit gas temperatures

By visual observation


Melt-down and loss of chains

Damage to kiln shell in chain system area

On wet process kilns; steam explosion

Thermal damage to kiln back-end equipment

Possible Actions

Warning: Under no circumstances should water be added at the feed end.

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Immediately reduce fuel rate to minimum (but don’t shut fuel off completely)

At the same time, reduce ID fan speed to obtain zero combustibles and less than 0.3% oxygen

Increase kiln speed and feed rate to maximum until the back end temperature is under control

On wet process kilns, clear all personnel from firing floor

Preventive Measures

Avoid operating the kiln for more than 10 minutes when there is feed shortage

Establish and enforce maximum permissible operating limits for intermediate and/or exit gas

temperatures

HEAVY RAIN OR THUNDERSTORMS


On kilns that are exposed to elements;

Loss of coating and collapse of refractory lining

Thermal damage and warping of kiln shell

Possibility of power failure

Possible Actions

If storm occurs shortly after a kiln shutdown;

Jack (turn) kiln more frequently or continuously on auxiliary drive

Start auxiliary power generator in preparation for a possible power failure

SUDDEN, HIGH POSITIVE HOOD PRESSURE

Possible Reasons

ID fan failure

Large ring or build-up broken loose inside kiln

Instrumentation failure of cooler air flow, cooler stack damper, or ID fan control

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Steam explosion on wet-process kilns


All personnel on firing floor is in danger

Thermal damage to equipment on firing floor and hood

Danger of backfire in coal system

Possible Actions

Immediately clear all personnel from firing floor

Immediately reduce fuel rate to minimum and increase ID fan speed

Reduce cooler air flow rates into under grate compartments

Open cooler excess air damper manually

OVERHEATED KILN BEARINGS

(Procedure needs to be approved by your Maintenance Department)

Slow down kiln speed near minimum 20 rph. Do not stop the kiln (bearing will seize)

Open reset door on top of bearing and pour in sulfur until noise stops

You can add also “powdered graphite” to the bearing lubricating oil

The sulfur must be poured on the shaft and not on the bearing casing

Keep a bag of sulfur near the control room location

Call the Maintenance Supervisor

Check if the oil heating is on or not, and stop it if it is in operation (breaker location must be known to

all)

Check if the water or glycol circulation is okay. If there is no circulation, open the water valve very slowly

If you cannot reach the Maintenance Supervisor, call for an Oiler and a Maintenance man

Install a water hose to get cold water in the bearing (not a close circuit loop)

Drain the oil and add new oil until the new oil has reached its normal temperature (below 120oF/50oC

you should have a temperature gauge showing the oil temperature on each bearing)

Temperature sometimes requires from 6 to 12 hours to reach 120oF/50oC

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Type of oil to use for the bearings to be confirmed by your maintenance department

KILN HAZARDOUS CONDITIONS

Shooting Rings with Gun

Do not allow any employees other than the gun crew on the firing hood during ring shooting

Do not tamper with the ammunition

Keep all live ammunition locked up and away from the firing floor when not in use

Permit only experienced and trained persons to operate the kiln gun

Use ear muffs when firing gun

Cotton stuffed in the ear is not adequate

Clean gun at frequent intervals and do not attempt to fire an apparent defective gun

If kiln has no chain section, keep all persons away from the kiln back end and rope this area off

before shooting

Clinker, Fuel Oil and Coal Dust Spills

Clean up spills immediately

Provide adequate clean-up cans and facilities for easy removal of spills

Initiate repair action when spills are caused by leaks that can be repaired

Gas, Fuel Oil, Coal and Steam Leaks in Fuel System

Report any gas odor on the firing floor immediately to the shift supervisor

Provide for periodic inspection of fuel and steam lines and system to detect leaks and other

defects as a preventive measure against major breaks in the system

Burner Hood, Porthole and Cooler Doors

Do not allow anyone to look into the burning zone while the kiln is on operation unless

approved safety equipment for viewing is used

Use proper protective clothing when working near open burner hood and cooler doors while the

kiln is in operation

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Instruct all persons to stay clear of the portholes whenever the hood pressure is temporarily on

the positive side

Relining the Kiln with Refractory Bricks and Materials

Use protective screen when working under loose refractory and coating, if no alternate

procedure is possible

Any employee working inside the kiln should have positive means, such as locking out the kiln

drive with his own lock, to assure that the kiln cannot be started while he is inside

Have proper posture and steady footing when lifting bricks or scaling coating

Do not work underneath the burner hood bridge while material is being hauled in and out of the

kiln

Do not test run cooler fans when workmen are inside the kiln

Do not run ID fan when workmen are at kiln rear or in chain section

Working Near or on Dust Collecting Equipment

Wear extra protective clothing to guard against burns from hot dust

Wash skin thoroughly with clear water after contact with alkaline dust

Have a second workman as safety man standing by whenever working under or in bins or

hoppers containing material

Do not allow workmen to work inside hopper without being properly secured on safety lines and

belts

When working on plugged flue hangers, be constantly on guard against potential dust flushes

and cave in of overhanging materials

Backfire and explosion During Kiln Light-up

Open either one cooler or burner hood door before lighting fire in kiln

Secure proper draft in kiln before fire is lighted (very important)

Do not allow unauthorized person to stand near the burner hood during light-up

Stay clear of burner hood ports when igniting the fuel

Avoid excessive fuel flow on initial light-up of flame

Start the primary air fan before opening the fuel valve

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When firing coal, make sure that no coal dust spills are present on firing floor, around coal

feeder, or in the primary air pipe

Setting any Kiln Machinery into Motion During Start-up

Make sure all persons are clear of kiln equipment before each unit started

Sound horn to signal startup

Inspect all circuit breakers before the startup to make sure that all safety tags and locks have

been removed

Make sure all machine guards are in place before any equipment is started

Relining the Kiln with Refractory Bricks

Construct a proper bridge across the burner hood from firing floor to kiln nose

Inspect coating and remove loose overhangs before passing underneath

Keep all unauthorized personnel out of kiln interior

KILN OPERATION SECTION

KILN OPERATION TECHNIQUES

There are Three Common Techniques for Burning Clinker in a Rotary Kiln

Maintain a constant kiln speed, and vary the fuel rate to counteract the temperature changes in

the burning zone

Maintain a constant fuel rate, and vary the kiln speed to hold the burning zone temperature at

the desired label

Vary the kiln speed, the fuel rate or both to maintain the desired burning zone temperature

These techniques have one error in common. They show concern only for the burning zone

temperature.

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Unfortunately, many kiln operators think that this is good enough, reasoning that, as long as good-

clinkers are produced, what more is necessary? The fallacy of this reasoning lie in the fact that ideal

stable kiln conditions can be obtain faster and more economically when equal consideration is given to

all zones in the kiln and not the burning zone alone.

The process of clinker burning, therefore the process of rotary kiln control starts not at the place where

the feed enters the burning zone but at the point where feed enters the kiln.

The Proper Operation Technique is:

Vary the kiln speed, the fuel rate and the induced draft fan in any combination to maintain the proper

burning zone temperature and maintain a constant back-end temperature for a given rate of feed. This

technique is called; “Burning a kiln from the rear”.

By doing so, you prevent the variations instead of reacting to them when they reached the burning

zone.

If you stabilize the kiln back-end temperature you will be able most of the time to overcome the burning

zone temperature variations mainly by using the fuel input to the kiln and the ID fan speed.

In long wet and dry kilns, kiln speed variations should be avoided as much as possible in normal

operation as it create variations in the material loading of the kiln and eventually could lead to the kiln

into an upset.

If kiln speed variations is to be used, then they should be small (1 to 3 rph) keeping in mind that the

material load of the kiln will be more or less +/- 2 hours later as it will reach the burning zone, (kiln

retention time).

However, speed variations must be used on pre-calciner kilns to control the burning zone temperature

as the calcinations rate or the feed preparation is done by the fuel input on the pre-calciner burners.

The feed/speed ratio must remain constant all the time once the perfect loading of the kiln has been

found. Speed/feed ratio should not be changed to control the kiln.

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BURNING ZONE EVALUATION

The burning zone condition can be estimated from the colors observed in the hottest part of the flame.

An orange-yellow color is normal.

When looking into burning zone, one will observe a sharp color change of the lowest part of the feed

bed under the flame from dark to bright.

This point in burning zone is of great importance to the operator as it is the earliest indication when the

burning zone tends to warm up or to cool down.

In normal operation, the position of the dark feed remains stationary approximately one quarter of the

distance into the flame. This point should be used at the main indicator for evaluation of the burning

zone.

If the dark feed move further under the flame (towards the front of the kiln) the burning zone is cooling

down.

If the dark feed shifts in the direction of the kiln rear the burning zone is warming up.

The position of the dark feed can feed can move because of changes in the flame shape, the feed

loading of the kiln or if the feed to kiln is harder to burn. Any change in the position of the dark feed

must be viewed in the light of all of these influences.

The operator must be able to see the dark feed whenever he looks inside the kiln and he must regulate

the operation of the kiln so as to achieve this;

A slow shifting of the dark feed in either direction can usually be counteracted by a small change in the

fuel input rate in order to keep the feed in its proper place.

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If it become necessary to counteract the condition in which the feed has slipped too far under the flame

than the kiln speed should be varied to restore the dark feed position to the proper location.

STABLE KILN TEMPERATURE PROFILE

When there is no movement (up or down) of the dark feed, and no changes were made on the kiln

speed, the fuel rate and the ID fan speed for the last 2 hours, and the back-end temperature has

remained stable than;

The kiln temperature profile should be considerately satisfactory and the kiln system stable,

Then the burning zone should be considered as set point for this kiln feed;

When the burning zone as reached this condition than the related back-end temperature, and gas chain

temperature should be considered as set point also for this kiln feed.

TARGET SET POINT AND OPERATION REFERENCES

Whenever the operator has achieved a perfect and stable temperature profile on the kiln system, the

value of the following sensors should be taken as references set point for future operation and are:

Back-end temperature

Gas chain temperature

Material chain temperature

Kiln amps

Burning zone temperature

NOx value

And these values need to be correlated to the main controllers on the kiln which are:

The feed rate to the kiln (and the type of clinker produced)

The kiln speed

The ID fan speed

The fuel rate to kiln

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The oxygen level

References and set point for operation need to be established on each type of clinker produced and this,

at the maximum feed rate on each kiln system.

Also a copy page of the kiln operation should be taken.

With all these references, the operator has all the tools to make an optimized kiln operation.

BACK END TEMPERATURE CONTROL

Back End Temperature is controlled principally by 3 factors;

ID fan speed - Change in kiln exit draft (oxygen level)

Fuel rate - Causing changes in heat input in kiln

Feed rate - From feed variations in feed ratio, kiln speed, or dust return rate to kiln

Back End Temperature control goes hand in hand with oxygen, fuel rate and burning zone control. As a

matter of fact, whenever the operator makes an adjustment in any one of the main control variables, he

has to consider the reaction that will take place in all regions of the kiln. Of these, the ID fan speed and

the fuel rate are the usual causes for changes in back-end temperature, as the feed rate should remain

constant.

THE THREE BASIC VARIABLES

Variable Conditions in the kiln are indicated by:

The Burning Zone Temperature or dark load position, NOx signal, and kiln amps level which has

the dominant influence on the clinker quality

The Back-End Temperature or the gas chain temperature which are the principal controls on the

operation stability

The Percentage of Oxygen in the exit gas, which governs the combustion and the fuel efficiency

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In most conditions, except for the emergencies or upset conditions, the operator will find that these

three variables can be maintained within reasonable limits by means of adjustments of one or more of

the 3 basic controls.

TARGET RANGES FOR THE THREE VARIABLES

Ranges for the Three Variables

For the kiln operation, it is necessary to establish target ranges for the three variables. This information

will be supplied by the past experience and depend on the raw mix composition, clinker type and other

factors.

These ranges has to be established where these variables can safely be permitted to fluctuate without

upsetting the kiln operation.

Examples of Values which have been established:

target range limits

Burning Zone Temperature 2800oF (1550oC) +/- 50oF

(+/- 50oC) 2750oF to 2850oF

(1500oC to 1600oC)

Back-End Temperature 1450oF (800oC) +/- 20oF

(+/- 20oC) 1430oF to 1470oF (780oC to 820oC)

Oxygen Percentage 1.2% +/- 0.8% 0.4% to 2.0%

THE THREE BASIC CONTROLS

Fuel flow to the burner

Change in the kiln speed

Change in the speed of the ID fan

The operator needs to use one or all of its three controllers to keep these variables inside their limits.

The operator must be alert and correct any out of range conditions as soon as it reaches the limits of

tolerance.

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Correction should be made promptly, but care must be exercised to avoid overreacting as this could lead

the kiln to an upset.

THE 27 CONDITIONS (KURT E. PERAY)

Because any of these variables can be within, below or above the allowable range, there are 27 possible

conditions that will be encountered by the operator.

These are shown graphically in the following figure. Note that a case number has been assigned to each

condition as an aid to identification. This chart should be used by the operators to understand the logic

of good kiln operation procedures where the Back-End Temperature, the Burning Zone Temperature

and Oxygen level were all taken in consideration in order to make a logic correction to an out of range

variable.

Case Condition Action to be taken Reasons

1 BZT low Ox low BET low

When BZT is drastically low, a) reduce kiln speed b) reduce fuel rate

When BZT is slightly low, c) increase ID fan speed d) increase fuel rate

a) to increase BZT and BET b) to move Ox percentage into range c) to raise BET and Ox d) to raise BZT and Ox into range

2 BZT low Ox low BET OK

a) reduce kiln speed b) reduce fuel rate c) reduce ID fan speed

a) to raise BZT b) to raise Ox percentage into range c) to maintain BET

3 BZT low Ox low

BET high


a) to raise BZT b) to increase Ox c) to reduce BET

4 BZT low Ox OK

BET low

When BZT is drastically low, a) reduce kiln speed

When BZT is slightly low, b) increase ID fan speed c) increase fuel rate

a) to raise both BZT and BET b) to raise BET and Ox c) to raise BZT

5 BZT low Ox OK BET OK

When BZT is drastically low and Ox is in lower part of range,


a) to raise BZT b) to raise Ox c) to maintain BET

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When BZT is slightly low and Ox is in higher part of range,

d) increase fuel rate

d) to raise BZT

6 BZT low Ox OK

BET high

When BZT is drastically low, a) reduce kiln speed b) reduce fuel rate c) reduce ID fan speed

When BZT is slightly low and Ox in higher part of range,

d) reduce ID fan speed

a) to raise BZT b) to raise Ox c) to lower BET d) to reduce BET and raise BZT

7 BZT low Ox high BET low

When BZT is drastically low, a) reduce kiln speed b) reduce ID fan speed

When BZT is slightly low, c) increase fuel rate

a) to raise both BZT and BET b) to maintain BET c) to raise BZT and lower Ox & BET.

BET should be rising also, if not keep increasing fuel rate and ID fan speed

8 BZT low Ox high BET OK

When BZT is drastically low, a) reduce kiln speed b) reduce ID fan speed

When BZT is slightly low,

c) increase fuel rate

a) to raise BZT b) to maintain BET. If Ox is still

available after this move, increase fuel also

c) to raise BZT and lower Ox

9 BZT low Ox high BET high

When BZT is drastically low, a) reduce kiln speed b) reduce ID fan speed c) increase fuel rate

When BZT is slightly low, d) reduce ID fan speed

a) to raise BZT b) to lower BET and Ox c) to raise BZT and lower Ox

d) to raise BZT and reduce BET & Ox

10 BZT OK Ox low BET low

a) increase ID fan speed b) increase fuel rate

a) to raise BET and Ox b) to maintain BZT

11 BZT OK Ox low BET OK

a) decrease fuel rate slightly a) to raise Ox

12 BZT OK Ox low

BET high

a) reduce fuel rate b) reduce ID fan speed

a) to increase Ox b) to lower BET and maintain BZT

13 BZT OK Ox OK

BET low


a) to raise BET b) to maintain BZT

14 BZT OK Ox OK BET OK

None, however do not get overconfident

15 BZT OK Ox OK

When Ox is in upper part of range,

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BET high a) reduce ID fan speed When Ox is in lower part of range,

b) reduce fuel rate c) reduce ID fan speed

a) to reduce BET b) to raise Ox c) to lower BET and maintain BZT

16 BZT OK Ox high BET low


a) to raise BET b) to maintain BZT and reduce Ox

17 BZT OK Ox high BET OK

a) reduce ID fan speed slightly a) to lower Ox

18 BZT OK Ox high BET high

a) reduce ID fan speed slightly b) reduce fuel rate slightly

a) to lower BET and Ox b) to maintain BZT

19 BZT high Ox low BET low

When BZT is drastically high, a) increase kiln speed b) increase ID fan speed c) reduce fuel rate

When BZT is slightly high, d) increase ID fan speed

a) to avoid overheating BZT b) to raise BET and Ox c) – do – d) to lower BZT and raise BET & Ox

20 BZT high Ox low BET OK

When BZT is drastically high, a) increase kiln speed b) decrease fuel rate c) increase ID fan speed

When BZT is slightly high, e) increase ID fan speed

a) to avoid overheating b) to lower BZT c) to increase Ox and maintain BET d) to lower BZT and raise Ox

21 BZT high Ox low

BET high

When BZT is drastically high, a) increase kiln speed

b) reduce fuel rate

When BZT is slightly high, c) decrease fuel rate

a) to lower BET and avoid

overheating b) to lower BZT and increase Ox

c) to lower BZT, BET and increase Ox

22 BZT high

Ox OK BET low

When BZT is drastically high, a) increase kiln speed b) increase ID fan speed c) reduce fuel rate

When BZT is slightly high, d) increase ID fan speed

a) to avoid overheating b) to raise BET c) to lower BZT

d) to raise BET and lower BZT (see

note A)

23 BZT high

Ox OK BET OK

When BZT is drastically high, a) increase kiln speed b) decrease fuel rate c) increase ID fan speed

When BZT is slightly high, d) reduce fuel rate

a) to avoid overheating b) to lower BZT c) to maintain BET

d) to lower BZT (see note A)

24 BZT high

Ox OK When BZT is drastically high,

a) increase kiln speed a) to avoid overheating & lower BET

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BET high b) decrease fuel rate When BZT is slightly high,

c) decrease fuel rate

b) to lower BZT c) to lower both BZT and BET (see

note A)

25 BZT high Ox high BET low

When BZT is drastically high, a) increase kiln speed b) increase ID fan speed

When BZT is slightly high, c) increase ID fan speed

a) to avoid overheating b) to increase BET and lower BZT

c) to raise BET & lower BZT (note A)

26 BZT high Ox high BET low

When BZT is drastically high, a) increase kiln speed b) increase ID fan speed c) decrease fuel rate

When BZT is slightly high, d) reduce fuel rate

a) to avoid overheating b) to maintain BET c) to reduce BZT

d) to lower BZT (see note A)

27 BZT high Ox high BET high

When BZT is drastically high, a) increase kiln speed b) decrease fuel rate

When BZT is slightly high, c) decrease fuel rate d) decrease ID fan speed

a) to lower BZT and BET b) – do –

c) to lower BZT d) to lower BET (see note A)

NOTE A: If the % O2 increased during this adjustment, disregard it until temperatures are brought under control.

KILN UPSET CONDITIONS – SLOW DOWN

Kiln cannot operate in a stable condition at all times and it will eventually get colder.

Sometimes heavy rush of feed might end up too far under the flame (halfway under the flame).

Operator must then decide if he will be able to control the heavy feed load only by increasing the fuel

flow, or if he needs to reduce the kiln speed.

The determinant factors to be considered are the oxygen level, back-end temperature, movement of the

feed rush, and conditions in the cooler.

Assuming that it is impossible to maintain the same kiln speed, the operator must determine how much

the kiln speed can be slowed down depending on the magnitude of the push.

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Only experience can tell the operator how much the kiln has to be slowed down.

In those cases the following rules apply all the time;

When in doubt, the kiln speed reduction should be greater than required. This will help to

overcome the problem faster.

Never allow the raw, unburned feed to enter into the cooler, even if it means that the kiln must

be stopped and rotated on ¼ turn or the auxiliary drive.

As soon as the kiln has been slowed down, the operator must;

Try to keep the back-end temperature within acceptable limits variation (i.e. 75 to 100oF).

Cut down the fuel flow to maintain the oxygen level above 0.5% and to keep back-end

temperature inside the limit range.

Evaluate the cooler conditions, grate speed, grate temperature, inlet temperature of gravel bed

collection system and secondary air temperature.

Often, the cooler will have to be switched on manual mode to protect it to become overheated

as often regulation of cooler are made for small variations only.

As the kiln is on slow speed, it is necessary to determine when the speed can be increased back again.

In that case, the oxygen level is the main factor to look at.

Try to keep the same values on the fuel flow and ID fan speed in order to observe the O2 variations.

When O2 level increases, the burning zone is warming up.

As soon as the oxygen level start to increase, increase the kiln speed slowly i.e. +/- 3 rph if the

burning zone is still dark and very dusty.

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Observe the reaction of the O2 level if it keeps on raising.

If so, increase kiln speed by 3 rph at every 10 minutes, and keep on increasing as long as the

oxygen level does not drop.

Keep fuel flow always one step ahead of normal operation level, (i.e. when rotation speed is at

24 revs, set fuel flow for 27 revs), and ID fan speed accordingly.

Stop increasing kiln speed approximately 1 ½ to 2 hours after initial slow speed in order to

overcome any upset in the material load of the kiln created by the speed variation.

Restart increase the kiln speed after reception of material from slowdown is over.

Kiln speed increase should be reduced around 80 revs as we are getting near full production (i.e.

2 revs at every 20 minutes).

When full production has been reached (i.e. 85 revs) the fuel flow must be kept one step higher

than normal for at least 2 more hours, and then it must be cut down slowly following the normal

operating procedures to get the load at the end of the flame again.

A slowdown made in time and at proper speed will requires about 20 minutes before to restart to

increase the kiln speed again (as O2 start to go back up).

Usually, the kiln should be back in full production about 4 hours after the slowdown was made.

Slowdown Example:

revs t/h Fuel flow ID fan speed O2 Operation

86 93 102 m3/h 530 rpm 1.5% Normal

66 72 85 m3/h acc. O2 level 0.7 Slowdown

36 40 50 m3/h acc. O2 level 0.7 slowdown

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NORMAL OPERATING PROCEDURES ON SHIFT

Take Over of Shift by Operators

Check:

Visual inspection of burning zone, look for dark load

Oxygen level and trend

Back-end temperature and trend

Kiln amps and trend

NOx signal and trend

Kiln speed

Kiln feed indicator

Secondary air temperature and trend

Clinker load on grate in cooler

Cooler fans under grate pressure

Kiln draft and hood pressure

Gravel bed filter or DC temperature

Water spray and precipitator

Then an evaluation of the kiln and burning zone state need to be done in order to compare actual

settings with the target value and limit ranges established before.

Wait at least 30 minutes before changing any values, unless there is an emergency condition in order to

evaluate if the kiln is warming up, cooling down or stable.

PLAN OF ACTION

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If the burning zone is hot (not drastically hot) and the kiln is stable

Decrease fuel flow by 3%

Then decrease ID fan speed to keep the same O2 level

Wait approximately 20 min (retention time of the burning zone) to see the reaction of your

move

Then repeat the same procedure again or stay there if dark load is moving in position or if the kiln amps

are dropping.

Repeat the operation until you get;

The dark load at the right position

The kiln amps inside its target range

The kiln gas temperature and back-end temperature inside their target range

If burning zone is cold (not drastically cold)

The same approach is to be done but in reverse

This procedure should be done on each shift in order to get the best kiln condition and the best heat

consumption possible at all times.

Whenever the dark load, the kiln amps and the kiln back-end temperature are back inside their target

range, then the 27 conditions procedures should be done again to maintain the kiln back-end and the

burning zone temperature on set point and the kiln temperature profile stable.

OXYGEN LEVEL IN AUTOMATIC MODE

When the perfect temperature profile balance has been reached, we can eventually set the oxygen level

on automatic (looped to the ID fan speed). This will allow the gas flow in the kiln to be constant and will

help to maintain the kiln system stability.

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Theoretically speaking, as we reach this situation, no more moves on the fuel rate, feed rate and kiln

speed need to be done and the kiln should remain in balance until an upset on the material load or a mix

change creates an upset again.

So the oxygen level control should be set on automatic whenever the temperature profile in kiln is

satisfactory. Every time this is not so or the kiln is slightly upset, the oxygen should remain in manual

and used to establish a good temperature profile inside the kiln.

KILN START-UP AND SHUTDOWN PROCEDURES

KILN PREHEAT

Light-Up Flame Example (gas)

1) Call the gas company to tell them that you are going to light up

2) Open one side of precipitator (inlet and outlet damper)

3) Start dust handling system on the side of precipitator in use with dust going to the ground (to

avoid plugging the circuit with moist material)

4) Start up ID fan at minimum speed (damper closed)

5) Open ID fan damper at 10%. Use a rag in front of kiln door to evaluate suction in the kiln and

adjust damper to obtain proper suction

6) Start primary air fan with damper closed

7) Install torch under burner pipe

8) Set natural gas to obtain approximately 13 m3/min (450 ft3/min)

9) Slowly open manual valve on gas line

10) Adjust primary air damper, primary and secondary gas pressure, and ID fan damper for best

flame possible

11) If flame goes out, make sure to purge the air inside the kiln before any attempt to try lighting up

again

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12) Don’t turn the kiln for the first 2 hours

13) Start nose ring fan one hour after the flame on

PRE-HEAT or Drying of the Refractory Lining

General Information:

The pre-heat period last around 12 hours. A minimum of 8 to 12 hours is necessary

The reference temperature during this period should be the kiln feed end temperature

The target temperature should be approximately 300oC or 575oF at the precipitator inlet

Start kiln rotation (1/4 turn) 2 hours after flame on

After make ¼ turn every 30 minutes until the end of pre-heat period

If New Castable was Installed:

Pre-heat period could take as long as 36 hours depending on the location and the quality of the castable

installed and could be divided in three periods as follows:

First Period:

For 12 hours with gas flow of 13 m3/min or 450 ft3/min

Do not exceed 170oC or 340oF at the filter inlet during this period

Two hours after the flame on, make ¼ turn every 30 minutes during the balance of this period

Second Period

For 12 hours, increase the precipitator inlet temperature so it could reach 230oC or 450oF

Make ¼ turn every 30 minutes during this period

Third Period:

For 12 hours, increase the precipitator inlet temperature to reach 300oC or 575oF


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HEATING (To reach temperature ready to put feed on)


The reference temperature is the gas chain inlet temperature

The target temperature should be approximately 40oC or 105oF lower than the normal operation

temperature

The rate of increase of the temperature should be approximately 50oC or 125oF per hour

The temperature increase per hour should be done according to the following:

Length of refractory installed;

Complete kiln: 35oC or 100oF per hour increase

Repaired burning zone: 50oC or 125oF per hour increase

Kiln rotation during heating:

1) ¼ turn every 10 minutes for 2 hours

2) Continuous turn on auxiliary drive for 2 hours

3) Rotation at 0.5 or 30 revs for 1 hour

4) Rotation at 0.7 or 42 revs until 15 minutes before feed on

5) Rotation at 1.0 or 60 revs 15 minutes before putting feed on

Oxygen level during this period should be kept between 7 to 10% in order to increase the back end

temperature to avoid the burning zone to get overheated. Burning zone should be pink in color.

The cooler system is usually down, leaving only the nose ring fan and the primary air fan running

During this period, it is most important to keep the greasing system on the kiln drive running

As soon as the kiln is running continuously, start cooling fans on the burning zone

Expansion of the Kiln and Tire

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Heating rate in large diameter kiln (>14’) should not be higher than 50oC or 125oF per hour to

allow both tire and shell to expand at proper rate

Clearance between tire and shell should be monitored during start-up

The larger the diameter of the kiln, the more care has to be taken to get it running

FEED ON KILN


Feed rate is approximately 50% of normal feed rate

Feed rate increase of about 5 tons every hour

Kiln speed should be maintained at 1.0 rpm or 60 revs until the material reaches the burning

zone (to get material in burning zone quick)

Target for chain inlet temperature; 800oC (1472oF) or 40oC (100oF) below normal operation

temperature

Set ID fan speed to maintain about 3% the oxygen level

Start high voltage on precipitator

Start remaining items on cooler system (all cooler fans with dampers set as required)

Maintain those settings until the start-up reactions occurs (push should take +/- 2 hours)

In order to promote good coating formation in the burning zone, stabilize the kiln at 1.1 rpm or

66 revs at about 70 tph for 24 hours

After this period, take the kiln up to optimum operation level with normal operation procedures

KILN START-UP PROCEDURES (AFTER BRICK JOB)

Preparations:

72 hours before light-up, call the gas company to tell them the date and the hour of the light-up

4 hours before light-up, make dry run on all equipment

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Check burner pipe and its installation

Center the burner pipe, or adjust 1” down and 1” towards the load (make marks outside the kiln

for the burner pipe position reference)

Check fuel on auxiliary drive

Take locks off on kiln equipment sets

Take off wood shims on kiln rollers

Pre-heat:

Start kiln section on CRT

Open one side of precipitator (outlet and inlet damper)

Start the dust handling on the side of the precipitator in service, with the dust on ground to

avoid plugging the circuit

Start-up ID fan at 125 rpm or minimum speed, damper closed

Open ID fan damper at 10%

Start primary air fan, damper closed

Install a torch under burner pipe

Set natural gas in control room at 13 m3/min or 450 ft3/min

Open manual gas on gas line

Open supervisory cock valve near burner pipe

Adjust primary air, primary and secondary gas and ID fan to get the best flame

One hour after, start nose ring fan and make no kiln rotation for the first 2 hours

The pre-heating period should last around 12 hours. A minimum of 8 to 10 hours is necessary. The

temperature at the inlet of the precipitator must reach 300oC or 575oF.

Special pre-heating after castable has been installed near the burning zone

First Period:

For 12 hours with gas flow of 13 m3/min or 450 ft3/min

No kiln rotation for the first 2 hours

Kiln rotation at ¼ turn every 30 minutes after 2 hours

Try not exceed 170oC or 340oF at the filter inlet during this period

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Second Period

For 12 hours, increase the back-end temperature so it could reach 230oC or 450oF


Third Period:

For 12 hours, increase the back-end temperature to reach 300oC or 575oF


HEATING-UP

The reference temperature is the chain gas temperature

The rate of increase of the temperature should be approximately 50oC or 125oF per hour

The target temperature should be approximately 40oC or 100oF lower than normal operation

temperature

Draw a curve on chain inlet temperature chart, so you could follow the temperature increase

Increase progressively fuel and draft (open second precipitator chamber when required)

The burning zone should be kept in place and should be pink when the feed will be put on

During that heating period, the oxygen should be between 7 and 10%

Start the water spray to keep the back end temperature at 350oC or 660oF

Around 750oC or 1400oF, start kiln feed for 10 minutes for testing

Check if any clinker on cooler grate and when necessary start the clinker evacuation system

Start shell fan when kiln is turning on continuously

Start cooler fan #1 and #2 at minimum 30 minutes before kiln feed

When you reach 800oC or 1475oF at chain inlet temperature (T according to plant normal

operation temperature minus 40oC or 100oF), start feed

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FEED ON

Start:

Kiln feed at 45 tons/hr

Kiln speed at 1.0 rpm or 60 revs

Increase;

Kiln feed at 5 tons per hour

Fuel rate and ID fan speed accordingly (maintain fuel rate 1 step ahead of normal operation)

Start fan #3, #4 and #5 (damper closed) 15 minutes after feed is on

Start gravel bed filter or its equivalent

Put tension on kiln precipitator 15 minutes after kiln feed is on

Stabilize the kiln at 1.1 rpm or 66 revs/hr at about 70 tph feed rate for 2 hours to promote good coating

conditions in burning zone

When increasing kiln feed, adjust the pressure and fan flow on cooler fans

Check closely the clinker evacuating system

When there is a good load in the cooler put the cooler on regulation

Kiln turns during heating:

¼ turn every 10 minutes for 2 hours

Continuous turn on auxiliary drive for 2 hours

Turn at 0.5 rpm or 30 revs/hr for 1 hour

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Turn at 0.7 rpm or 43 revs/hr until 15 minutes before putting feed on

Turn at 1.0 rpm or 60 revs/hr 15 minutes before feed on

EXAMPLE OF HOW TO START KILN IF PRE-HEAT IS REQUIRED (Load in kiln)

If pre-heat is required (Function of burning zone and gas chain temperature)

Open dampers on precipitator (both side)

Fuel rate at 44 m3/min or 1554 ft3/min

ID fan speed at 25 rpm (minimum speed)

ID fan damper position according to O2 level (5% maximum)

Maintain these settings until temperature reach on gas chain temperature at 850oC or 1562oF (normal

kiln operation temperature).

Kiln rotation varied according to gas temperature as follows:

If;

Chain Gas Temperature Rotation Fuel Rate

750 to 930oF ¼ turn every 20 minutes 44 m3/h or 1553 ft3/min




Then start the;

Kiln at 60 revs

Feed at 63 tph

Fuel at 88 m3/min or 3108 ft3/min

ID fan speed at 350 rpm and to maintain O2 near 4%

Start burning zone cooling fans

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Wait at this setting to receive the material and then increase slowly like normal procedures but always

maintain on fuel and ID fan speed settings one step ahead.

During this period, the nose ring fan is on.

The primary air fan is on with normal setting.

The cooler fans #1 and #2 on cooler are running.

Grates, clinker circuit and gravel bed filter are running.

Guidelines:

For a shutdown less than 5 hours, warm-up period should be around 1.5 to 2 hours.

For a shutdown between 5 to 12 hours, warm-up period should be around 4 hours.

EXAMPLE OF HOW TO RESTART IF NO PRE-HEAT IS REQUIRED

Start-up speed is related to the gas chain temperature of the kiln and burning zone aspect.

Start-up could be as follows:

If;

Chain Gas Temperature Rotation Rotation Fuel Rate

1435oF 60 revs 65 tons/hr 3110 ft3/min




1580oF* 78 revs 82 tons/hr 4025 ft3/min

*1580oF being the normal operation temperature

Adjust draft and fuel as required.

After material reception, increase according to normal procedures but keep 1 step ahead on fuel and ID

fan settings for 2 hours after you reach normal production level (retention time of material in burning

zone).

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This procedure is to be developed in order to restart a kiln faster and having less perturbation in the

material load of the kiln (long dry and wet kilns).

KILN SHUTDOWN (General Information)

There are many reasons why kiln must be shutdown periodically and in most cases, the operator must

decide when an immediate unscheduled shutdown of the kiln system is required. There is often not

enough time available in such situation to weigh or discuss the merits of a shutdown because a few

minutes of delay could lead to major equipment damage.

So clearly, an operator should be fully trained in what to do and what to do if such situation occurs.

Written standard procedures to cover these situations should be at the disposal of the operators to

allow them to review those procedures periodically.

COOLING PROCEDURES

In case of a shutdown, slow cooling of the refractory must be ensured.

The Stacks Registers:

Must be kept shut for a sufficient period of time

Cooling schedule should provide gradual cooling of the burning zone refractory at a maximum

temperature rate of 100oC (212oF) per hour

For smaller kiln, i.e. diameter < 13’, maximum rate is 100oC or 212oF

For larger kiln, i.e. diameter > 13’, maximum rate is 75oC or 167oF

The ID fan;

Should be shutdown immediately as soon as fire is cut off

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Should not be used for forced cooling at least for the first 12 hours after kiln shutdown

This is an absolute must on long dry and wet process kilns equipped with internal heat

exchangers such as chain

The ID fan inlet damper should also be closed completely for at least 12 hours

During short shutdown;

The kiln back-end should be closed completely for at least 12 hours

During short shutdown;

The kiln back-end should be closed completely to avoid hot gases to escape from kiln

Hood Pressure:

Flow adjustments on the cooler fans have to be made to avoid the kiln hood to get on to high

pressure

The hood pressure set point should be set slightly on the positive side to prevent air from

burning zone to escape through the cooler exhaust fan

KILN ROTATION SCHEDULE

The kiln must be rotated on a regular schedule to insure uniform cooling, as the feed bed and the

refractory underneath it, take more time to cool down than the refractory wall exposed to the kiln

gases.

Kiln Rotation for Short Maintenance Repair

¼ turn every 5 minutes 4 times during 20 minutes

¼ turn every 10 minutes 4 times during 40 minutes

¼ turn every 15 minutes 8 times during 2 hours

¼ turn every 30 minutes 8 times during 4 hours

¼ turn every 60 minutes until the end ----------------

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If it is Raining,

Continuous rotation should be done on the auxiliary drive or on main drive at minimum speed

Kiln Rotation for Long Kiln Shutdown (brick lining repair)

Before:

Stabilize kiln rotation at 1.0 rpm or 60 revs before shutdown (flame still on)

Then:

Maintain continuous rotation at 0.6 rpm or 36 revs during 30 minutes (flame is off)

Maintain continuous rotation at 0.5 rpm or 30 revs during 2.5 hours

Maintain continuous rotation at 0.4 rpm or 24 revs during 1 hour

Maintain continuous rotation at minimum speed on auxiliary drive for 1 hour

Then:

If it is raining, continuous rotation should be done on the auxiliary drive or at minimum speed on main

drive.

Shutdown for long periods also included purging of the following:

Fuel firing system

Feed system

Dust system from precipitator or dust collector system

Dust system of conditioning tower

Clinker from cooler system

BURNER PIPE AND HOOD PROTECTION

The burner pipe must be protected as the hood and the kiln discharge area remains at high temperature

for several hours after the fire has been cut off.

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Some kilns are equipped with movable burner pipes to allow partial or full retraction of the burner.

Others have to rely on primary air fan to provide necessary cooling of the burner.

Primary air fan and nose ring fan should be running at least 10 hours after the flame has been cut off.

EMPTYING THE FEED FROM THE KILN

Emptying the feed from the kiln takes special skills and experience. It could be very dangerous and could

result directly in overheating conditions either at the back-end of the kiln, the burning zone, or the

cooler. So called “chain and coal mill fires” have occurred as direct result of attempting to burn out a

kiln.

Therefore, burning out a kiln is far too risky and should never be attempted.

As soon as the feed is cut off, the flame should be cut off.

KILN SHUTDOWN PROCEDURES (FOR BRICK JOB OR RED SPOT)

Time (- 2 hours) Cut down kiln speed at 1.0 rpm or 60 revs

Time (- 15 minutes) Cut off coal extraction from silo if required

Time (- 5 minutes) Cut off feed extraction from homo silo

Time (- 2 minutes) Cut off high voltage on precipitator

Time (0 hour) Cut off feed and purge circuit completely

Cut off fuel when system is purged

Time (+ 2 minutes) Stop ID fan

Reduce air flow under cooler

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Time (+ 4minutes) Close ID fan louvers slowly, or equivalent equipment

Adjust cooler fans to keep hood pressure slightly positive

Stop water spray system or any water system at back-end

Time (+ 6 minutes) Cut down kiln speed at 0.6 rpm or 36 revs

Reduce primary air fan (1000 Pascals or 10 mbars)

Put cooler system on manual mode

Reduce grate speed at 4 strokes per minute

Reduce fan #1, #2 and #3 at 50% of normal air flow

Reduce other fans according to gravel bed filter inlet temperature or

Other de-dusting system

Time (+ 10 minutes) Close main damper on precipitator, (line 1 & 2) or any equivalent

equipment

Keep the extraction of the dust system running

Keep nose ring fan running

Time (+ 15 minutes) Retract burner from kiln hood if possible if not keep primary air fan

running for cooling

Time (+ 30 minutes) Reduce kiln speed to 0.55 rpm or 33 revs

Pull water spray out of the kiln

Time (+ 1 hour) Reduce cooler fans #1, #2 and #3 to 25% of normal flow

Reduce other fans according to gravel bed filter inlet temperature or

other de-dusting system

Time (+ 1.5 hour) Reduce kiln speed to 0.5 rpm or 30 revs

Watch for unburned clinker and send it to proper location

Time (+ 2 hours) Stop cooling fans under kiln shell

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Readjust air flows under cooler

If possible, stop last fan according to filter inlet temperature

Time (+ 4 hours) Reduce kiln speed to 0.4 rpm or 24 revs

Time (+ 5 hours) Stop rotation with main motor

Start continuous rotation with the auxiliary drive

Stop extraction of dust on the precipitator or dust collector system

Time (+ 6 hours) Stop continuous rotation with the auxiliary drive

Make ¼ turn every 15 minutes (attention to greasing system in the main

kiln drive to be started in manual)

Time (+ 8 hours) Make ¼ turn every 30 minutes

Time (+ 10 hours) Stop nose ring fan and primary air fan

Time (+ 12 hours) Make ¼ turn every hour

Time (+ 15 hours) Stop cooler fans

Stop gravel bed filter system if required

Time (+ 16 hours) Open main damper on one side of the precipitator

Start the ID fan a few seconds with damper closed every hour

Time (+ 18 hours) Start ID fan a few seconds




Open door on kiln hood

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Open ID fan at 75%

Time (+ 24 hours) Close ID fan completely

Time (+ 26 hours) Start ID fan at minimum speed

Open ID fan at 10%

Time (+ 27 hours) Open ID fan at 30%



Time (+ 30 hours) Open ID fan damper completely

Stop kiln rotation completely

Start to open kiln hood front door

Make security on kiln system (lock procedures)

Start to clean cooler system

This shutdown procedure could also be used as an emergency shutdown on red spot.

CLINKER COOLER SECTION

COOLER

FUNCTION

a) The main function of the cooler is to recuperate the heat contained in the clinker coming from

the kiln as heat recovery from secondary, tertiary and to coal mill air is important for kiln

efficiency and fuel saving.

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b) The cooler must also lower the temperature of the clinker before it leaves so it can be safely

transported to the storage area

c) The clinker breaker at the cooler outlet reduce the clinker size so it can be transported on the

conveyor system

COOLER OPERATION

Cooling of the clinker material is accomplished by forcing ambient air upward through the material as it

is being conveyed through the length of the cooler by reciprocating action of the grates.

The clinker cooler is divided into two major areas, which are separated by the grate line. They are the

over grate area where the clinker is cooled down and where the hot gases are handled and the under

grate compartment where cooling air is blown into the system.

The grate line consists of many perforated grate plates arranged in overlapping rows. The alternate rows

are movable and are connected to a wheel mounted frame which is moved back and forth on its tracks

by a crank type drive that drives the grates their reciprocating motion. See figures 2 to 6.

In normal operation, the cooler is running in auto to keep a constant under grate pressure and air flow

under the second compartment in order to control the secondary air temperature.

However under upset conditions, the cooler must be switched on manual.

COOLER CONTROLLERS

In normal operation:

The speed of the grate change the residence time of the clinker inside the cooler (to control the

cooling rate of the clinker and to protect the grate to get overheated)

The air flow distribution under each compartment to maintain good heat recuperation and good

cooling of the clinker

In case of emergency: (such as a badly overheated cooler condition, the operator must always)

Decrease the kiln speed in order to reduce the clinker input to the cooler and control the heat

input

OPERATION OBJECTIVES

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To keep as much as possible:

The clinker temperature at the cooler discharge as low as possible (high temperature could

damage the clinker transport system)

The secondary air temperature as stable and as high as possible to get the best recuperation

from the clinker and improve the fuel efficiency of the kiln

To keep the depth of the clinker bed near 15” water gage in order to get good heat recuperation

from the clinker in cooler (according to fan capacity)

To keep the hood pressure always slightly negative

To set the cooler fans flow in such away to have enough capacity to get air through the clinker

bed and to insure proper cooling of the grates and the clinker load inside the cooler

Cooler settings should be such that bed grates, cooler drive unit, clinker crusher, cooler wall and clinker

conveyors system cannot become overheated.

RULE IN COOLER OPERATION

A fundamental rule on grate cooler is to never permit raw feed or extremely fine clinker to enter the

cooler as the cooler can become overheated and damage.

During kiln pushes, lower the kiln speed in order to reduce fine clinker input in the cooler.

Never run the kiln with positive pressure as this result in troubled kiln operating conditions as:

Fine clinker in nose ring resulting to wear of kiln seal

Viewing in kiln is unpleasant and unsafe

Could damage the optical equipment and the TV camera

Formation of rings and “snowmen” in cooler inlet can be attributed to positive pressure

Exception: One exception to this rule if ever very high temperature in cooler and if needed to introduce

sufficient air in cooler.

MAIN SENSORS

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The Main Sensors to Control the Cooler Operations are:

The fans flow for each compartment

The under grate pressures under grate #1 and #2

The secondary air temperature

The grate speed under grate #1 and #2

The clinker discharge temperature at the cooler outlet

Also Secondary Sensors as:

Grate temperature in #1 and #2 compartments

TV camera showing the cooler interior

Hood Draft

Control by regulation the excess air inside the cooler by the cooler exhaust fan damper

It maintains a constant pressure in front of the kiln

A good hood pressure regulation is important for the burning zone stability

Assuming other Factors Remain Constant:

An increase in the ID fan speed will lower the hood pressure

A decrease in the ID fan speed will increase the hood pressure

Also increasing the amount of air in cooler results in higher hood pressure

Under Grate Pressures and Air Flow Rates

The under grate pressure is govern by the following factors:

Depth of the clinker bed over the grate

Average particle size of clinker in the cooler

Amount of air flow into the cooler

Should be at 15” water gage (under 2nd compartment) to get good heat recuperation

Clinker Bed Depth

The depth of the clinker bed is controlled by the speed of the cooler grate

The faster the grate, the thinner becomes the bed and lower is the under grate pressure

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Because of the relation between the grate speed, bed depth and under grate pressure, it is

possible to maintain a constant under grate pressure by regulating the grate speed

It is usually done under the second compartment of the cooler because it is that location at the cooler

inlet where the clinker bed is more stable and give an early and good under grate pressure signal for the

automatic cooler control.

PARTICLE SIZE OF CLINKER

A critical factor in under grate reaction is the average particle size of the clinker in the cooler.

A fine clinker bed impose more resistance against air flow, when the under grate pressure

increase, the fan has to use more force to push the air through this kind of bed

Then the under grate pressure increase when the clinker gets finer because the smaller particles

impede the air flow through the bed

Therefore, the airflow rate is increased to restore the normal flow through the bed and the

clinker bed can become fluidized

A fluidized clinker bed is highly undesirable and dangerous, because the bed in such a state does

not move along properly in the cooler

On horizontal grate, the clinker tend to remain stationary and tend to build on top of the grates

and when sufficient weight has been acquired by the bed, it starts to move again

So the clinker cannot be properly cooled down and could choke off the airflow through the bed

OPERATION OF COOLER FANS

The air volume for cooler fans is most commonly carried out by means of fan outlet damper.

The fan speed is constant so it is necessary to change the position of the damper to reduce or to

increase the air moved by the fan.

Fan damper is normally open at 60% as necessary leeway is required to increase air flow.

Maximum air flow is when the fan damper reached about 88% open.

The air volume output is directly related to the under grate pressure.

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The fan must have sufficient capacity to provide necessary amount of air at maximum under

grate pressure.

The maximum operating under grate pressure needs to take into account the cooler fans

capacity.

Flow rate for each fan and under grate pressure set point need to be set on for a good cooler

operation.

The fan manufacturers provide performance curve for each compartment fan.

Fan Static Pressure

Fan static pressure is the total pressure developed by the fan, less the velocity pressure in the fan

discharge duct.

For practical purposes, fan static pressure in a cooler system is equal to the under grate pressure, and

the air flow is a function of this static pressure and the power applied to the fan. (Figure 7)

Whenever the under grate pressure exceed the limit of the fan, the flow decreases and less cooling is

taking place then the cooler could be damaged.

CLINKER AND AIR DISTRIBUTION

For proper cooling, it is essential that clinker is evenly spread over the width of the cooler so that the

bed offers a uniform resistance of the air passage through its width.

When clinker passes to one side of the cooler leaving a thinner bed on the other side, the air will

naturally seek a passage through the bed where it offers the least resistance.

So air passes through bed where it is least needed and little air passes where it is needed most.

Formation of “snowmen” at the cooler inlet is the prime cause of this condition.

Various devices as dead grate, spreaders or grate with their own air supply to spread the clinker

rapidly over the width of the cooler inlet are used to fight “snowmen” formation.

For proper air distribution and good cooler regulation, no air should freely pass from one cooler

compartment to another through leaks or other opening on the compartment walls.

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The under grate pressure is usually set that the highest pressure is found in the first

compartment, and the lowest in the last compartment.

Emergency High Clinker Temperature

Installed on the drag conveyor is this sensor to measure the clinker temperature at the cooler discharge.

If the clinker temperature is above 300oF (150oC), it will transfer the clinker to the emergency bin

automatically and will stay there until the desired temperature will come back. High clinker temperature

is caused by inadequate cooling of clinker in cooler.

Guideline:

In cooler normal operation, no red clinker should be seen passing the third compartment.

COMBUSTION SECTION

FLAME

A flame is a stream of gases at extremely high temperature (around 3500oF or 1930oC) where the

reactions of combustion of the fuel with secondary and primary air are taking place. Anything exposed

to such a flame is bound to receive heat from it.

Flame Evaluation

Should always be evaluated during stable kiln condition

Flame Length

Could refer to the distance between the burner tip and the end of the flame which is a total

flame length

It could also refer to a distance between the point where ignition of the fuel start and where the

reaction of fuel combustion ends

It is desirable to operate a kiln with the flame as short as possible, as long as it will not create

problem in front of the kiln, hood, nose ring and refractory (Figure #1)

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Flame Shape

Could be long and “lazy” as heat is released over a relatively long distance (example A)

Could be “snappy” as heat is released over a shorter distance (example C)

Flame Direction

The flame path is not a straight line

The flame has a tendency of lift upward toward the top resulting in uneven entrance of

secondary air, or mechanical condition of the primary air pipe nozzle

A good direction target for the flame could be 2A or 2B in Figure # 2, or one inch down center

line and one inch towards the material load

The flame temperature is related to:

1. Quality and type of fuel used

Gas: 1830oC or 3325oF

Fuel oil: 1956oC or 3553oF

Coal: 1927oC or 3500oF

2. Total combustion air temperature

Secondary air temperature

Primary air temperature

Air in-leakage temperature

3. Oxygen level at kiln outlet

4. Brick and coating temperature in the burning zone

Flame Target

Ignition as quick as possible

Highest flame temperature as possible

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Length as short as possible

As constant as possible

Primary air flow minimum to carry fuel in kiln

All above combined in such a way for not making erosion and direct contact of the flame on the

refractory

Shell temperature scanner is a good indication of flame profile.

Flame Adjustment

Increase in primary air

The speed will increase

Temperature will increase

The volume will become wider

Increase in primary air temperature

The plume will get shorter

The flame will become shorter

The flame will become wider

Increase in secondary air temperature

The flame temperature will increase

The flame length will decrease

The plume will decrease

Increase on the oxygen level

The flame length will increase

The flame temperature will decrease

The following factors serve to raise the flame temperature:

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Increasing the secondary air temperature

Using less primary air, thus making it possible to utilize more secondary air which is preheated

to higher temperature

Promoting rapid mixing of the air and fuel upon leaving the burner by improving the design of

primary air pipe and burner

Better atomization of the fuel oil by increasing the fuel oil temperature or employing a

mechanical device in the burner nozzle to bring a better atomization

By keeping hood pressure as close as possible from “0” in order to avoid air in-leaking in front of

kiln

Operating the kiln with neither a deficiency or excess of air by maintaining the oxygen content

of not less than 0.7% and not more than 3.0%

Rules on Flames

a) When the primary air pipe nozzle has accidentally been warped, resulting in an erratic flame

shape and direction, immediate steps should be taken to repair this condition

b) A flame should never be allowed to impinge upon the coating or bare refractory for a prolong

length of time

c) A flame should never be allowed to strike too hard upon the feed bed

d) Oil burners or gas burners should be centered well in the primary air pipe in order that an even

envelopment of air around the fuel jet takes place

e) Flame direction should be adjusted only when the kiln is in stable operating conditions and the

temperatures, fuel pressures, and air flow rates are at normal level. Flame direction changes can

be caused by unusual operating conditions. If any attempt were made to adjust the flame at

such a time, there will most likely be an undesirable flame once the kiln returns to normal

operating conditions again

f) It is better to make the desired adjustments in flame direction in several small steps instead of a

large one in order that the operating stability of the kiln is not affected adversely

g) Once the ideal flame direction has been obtained, the primary air pipe position should not be

changed unless a definite reason (such as to combat a ring formation or hot shell conditions)

makes it desirable

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h) To protect the primary air pipe from possible damage during a shutdown, a certain amount of

primary air flow must be maintained until the temperature inside the kiln is low enough

(approximately 600oF or 315oC) that the pipe cannot be damaged. Upon power failure when

primary air fan stops, the primary air pipe must be immediately removed from the burner hood.

COMBUSTION

What is combustion?

Rapid combination of oxygen with fuel resulting into heat

Fuels contains,

Carbon

Hydrogen

Sulfur

Oxygen Comes from Combustion Air

Carbon + Oxygen = Carbon dioxide + heat

Hydrogen + Oxygen = Water vapor + heat

Sulfur + Oxygen = Sulfur dioxide + heat

Proper Proportioning of Fuel, Oxygen and Heat

Perfect combustion

Combustion air = Neutral (stoichiometric) combustion air

Deficiency of Air (Reducing Conditions)

Incomplete combustion

Heat released is low (4500 Btu vs. 14500 Btu per lb carbon)

Unsafe operation (explosion in precipitator or anywhere in the system)

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Excess of Air (Oxidizing Conditions)

Complete combustion

Flame temperature decreases with increasing air, lower fuel economy

Recommended back-end oxygen is 1.0 to 1.5%

Combustion Air + Fuel = Combustion Gases

Combustion Air = Primary Air + Secondary Air + Leakage

Combustion Gases:

Carbon monoxide (CO) with incomplete combustion

Carbon dioxide (CO2) with complete combustion

Water vapor (H2O)

Sulfur dioxide (SO2)

Nitrogen (N2) from air

Excess oxygen (O2)

Good Combustion Requirements:

Proper proportioning of fuel and air

Thorough mixing of fuel and air

Initial and sustained ignition of the mixture

Mixing of Fuel and Air

Good mixing is important for mixture to be uniform throughout

Every particle of fuel must be in contact with an air particle

Solids must be pulverized to increase surface area for mass transfer

Liquids must be atomized (breaking up into tiny particles) to speed up evaporation (resulting to

vapors burn as gases)

Process of starting combustion

Can start at low temperatures, but may not be sustained

Minimum ignition temperature required for sustained ignition

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(Ignition continues without any external source of heat)

At this point:

Heat from Reaction > Heat Lost to Surroundings

Fixed carbon:* 400 – 450oC or, 752 – 842oF

Volatile Matter: 500 – 600oC or, 932 – 1112oF

C & H (methane): 632oC or, 1170oF

Coke: +/- 800oC or, 1472oF

Fuel oil: 200 – 300oC or, 392 – 572oF

* can be considered ignition temperature of coal

Theoretical Flame Temperature:

Tf = LHV / (NCA + 1) S

Where Tf = Maximum (theoretical) flame (in oC or oF)

LHV = Fuel low heating value (in kg/kgf or Btu/lbf)

NCA = Neutral combustion air (in kg/kgf or Btu/lbf)

S = Specific heat of combustion gases (=/- 0.29)

Typical Fuel Data:

Fuel LHV

Kg/kgf (Btu/lbf) NCA

Theo. Max. Flame T oC (oF)

Coal 6500 (11,700) 9.1 2460 (4460)

Oil 9870 (17,770) 13.7 2480 (4500)

Gas 11,500 (20,700) 16.6 2400 (4350)

Influences and Impact on Flame Temperature

Impact of Oxygen content of Kiln Gases on Flame Temperature (Figure #3)

Oxygen 1% 5%

Flame To 2465oC 1965oC

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Impact of Secondary Air Temperature on Flame Temperature

Sec. air To 420oC (770oF) 845oC (1553oF) 1093oC (2000oF)

Flame To 2180oC (39560oF) 2445oC (4433oF) 2610oC (4730oF)

HEAT TRANSFER IN A ROTARY KILN

Radiation (Flame Zone)

Flame/Gas by Material

Flame/Gas by Kiln shell

Very important because heat transfer x (Tf4 – Tm4)

Conduction

Wall to Material

Chain/crosses to Material

Convection

Gas to Material

Gas to Wall

BURNER PIPES AND NOZZLES

What is required from a burner?

A stable flame with proper geometry

Versatility

Safety

Parameters Affecting the Flame

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Fuel characteristics

Primary air and secondary air

The burner design

Key Parameters of Burner Design

Number of circuits

Primary air Quantity

Ejection velocities

Minimum velocity

Back pressure

Specific impulse

Diameter

Number of Air Circuits (Figure 1 to 6)

Single Circuit

Control is minimal

High velocity requires high fan pressure

Results in more wear

Two Circuits

Swirl + high velocity transport air

Additional control due to swirl

High fan pressure, high wear rate

Three Circuits

Swirl + high velocity axial

Low velocity transport air

More versatile

Primary Air Quantity

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Natural gas: 0 to 7% of total combustion air

Liquids: 7 to 10% of total combustion air

Solid fuels: Firing system dependent

Direct firing system: 30 to 35% of total combustion air

Semi-direct firing: Mill exit air is 18 to 25% (moisture dependent)

Air to burner can be controlled by diverting

“Overflow” to kiln hood

Indirect firing: 7 to 12% of total combustion air

Theoretically, indirect firing is the ideal solution.

Ejection Velocities

Gaseous and liquid fuels (with atomizing fluid)

Sonic range: 330 m/s (1083 ft/s)

Solid fuels

Single circuit: 50–80 m/s (164–263 ft/s)

Multiple circuits: 80–170 m/s (262–558 ft/s) for axial

50–90 m/s (164–295 ft/s) for swirl

20–50 m/s (65–164 ft/s) for transport

Minimum Velocities

Required to prevent solid fuel accumulation, 20 m/s (66 ft/s) in transport line and in axial $ swirl

annulus if these streams carry any fuel dust

Knowing the minimum flow rates, the pipe sizes can be determined.

Back Pressure

Typical values for a three-circuit burner;

700 – 1000 mmH2O for axial air

150 – 600 mmH2O for swirl air

600 – 1000 mmH2O for transport air

(up to 1200 mmH2O for modified three-circuit burner)

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Specific Impulse

Typically, 4 to 8 N/Gcal/h

Definition

Sp. impulse = Impulse (Newton)

Heat input (Gcal/h)

For Solid Fuel;

Impulse = air stream mass flow rate (kg/s) x tip velocity (m/s)

For Gaseous and Liquid (pneumatically atomized) Fuels;

Impulse = (abP – c) S

Where: P = pressure (bars)

S = cross-section area (mm2)

a,b,c are atomizing fluid dependent

* 5 figures of burners to be attached at the above information.

FUELS IN THE CEMENT INDUSTRY

Solid Fuels:

Coal

Coal tailings

Petroleum coke (fluid, delayed)

Wood

Tires

Municipal waste, etc.

Liquid Fuels:

Oil (bunker C)

Liquid waste

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Coal slurry, etc.

Gaseous Fuels:

Natural gas (95% methane)

Landfill gases, etc.

Heating Value

Quantity of heat generated from 1 unit (kg, lb, ton, m3, liter) of fuel

Measured in kcal/kg, Btu/lb, MJ/ton, MJ/m3, kcal/liter

Can be approximated from the fuel composition

High Heating Value (HHV) vs. Low Heating Value (LHV)

High (or gross) Heating Value

Heat produced at constant volume by complete combustion of fuel, combustion

product condensed to liquid state, measured in the laboratory in an “oxygen

bomb calorimeter”.

Low (or net) Heating Value

Calculated from HHV by subtracting the latent heat of vaporization

The difference between HHV and LLV depends upon the hydrogen content of the fuel.

LHV = HHV - 92.7 x % H2 (Btu/lb)

Examples of HHV and LHV for Various Fuels

Fuel % H HHV

Btu/lb LHV

Btu/lb (% of HHV)

Coal 5 12,000 11,540 (96%)

Coke 4 14,000 13,630 (97%)

Waste fuel 10 9,000 8,070 (90%)

Fuel oil 10 19,000 18,070 (95%)

Natural gas 25 23,300 20,680 (90%)

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SOLID FUELS

Coal, oil, gas and in recent years, petroleum coke are the main fuels used in cement kilns.

Coals are judged on what is called an proximate analysis which tells the percentage moisture, volatile

matter, fixed carbon, ash, sulfur, and heat value.

Coal is very complicated in structure, containing carbon, hydrogen, oxygen, nitrogen and sulfur in

various stages of combinations.

With the application of heat, these substances from various combustible gases are classed as volatile

matter. It is the first constituent of the coal to be liberated on heating.

The carbon that remains after the volatile matter is driven off is called fixed carbon.

Combustion is the chemical combination of oxygen with certain elements of the fuel to form compounds

with the release of heat. See figure below.

Every combustible substance has what is called an ignition temperature.

This is the temperature to which it must be raised before chemical combinations with oxygen or

combustion will take place.

These combinations liberate definite amounts of heat depending on the elements entering into the

combinations.

The principal combustible elements in coal are carbon and hydrogen. Any sulfur present is also

combustible, but is of minor importance from a heat standpoint.

The chief non-combustible elements in coal are silica, alumina and iron which form the ash.

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Bomb Calorimeter

The heat value of coal can be determined by using the bomb calorimeter. A precise amount of dry coal is

fired in an oxygen atmosphere in a sealed container which is immersed in a water bath. The change in

temperature of the water is measured and knowing the specific heat of water (1.0 Btu/lbm*oF) the heat

content of the coal is determined.

Volatile Matter (VM)

Portion of solid fuel liberated as gases and vapors, when it is heated in the absence of air. (result from

thermal decomposition)

For good coal: VM = 30 – 35%

For fluid coke: VM = 5 – 6%

Combustion start to be difficult when VM < 15%

Fixed Carbon (FC)

Residue left after volatile matter is driven off.

FC = 100 - (VM + Ash + Moisture)

For bituminous coal: FC = 40 – 60%

Coke: FC = 75 – 85%

Ash

Residue remaining after the fuel has been burnt.

Composed of compounds of silicon, aluminum, iron and calcium

Also some traces of Mg, Na, K and Ti.

Proximate Analysis

Determination of VM, FC, ash and moisture

Used for quick, preliminary appraisal of solid fuel

Ultimate Analysis

Quantitative determination of moisture, C, H, S, O and N

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DRYING, GRINDING AND FIRING SOLID FUELS

Ball Mill or Roller Mills are used.

Air from cooler / air heater / pre-heater exit is used for drying.

The drying systems can be; (Figure # 1, 2, 3)

Direct

Semi-direct

Indirect

Comparison of fuel drying system

Direct Semi-direct Indirect

Simple operation Most difficult to operate Simple operation

Relatively safe Safer than indirect Safety is most important

Primary air is high (30-35%) All moisture to kiln

Primary air is low but all moisture to kiln

Primary air can be as low as desired (operation independent)

Result in high heat consumption

Heat penalty is lower than direct

Good heat consumption

Lowest capital cost Capital cost is in between direct and indirect

Highest capital cost

Liquid Fuels

Essentially composed of C, H, and S

Evaporation at 200-300oC or 572oF

Atomization promotes evaporation

Classified according to:

Viscosity (measure of internal friction)

Specific gravity

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Heating value

Gaseous Fuels

Natural gas most commonly used (95% methane)

No preparation required for firing

Minimum ignition temperature (+/- 650oC or 1200oF)

Very little primary air is required

Injected at high pressure (i.e. high tip velocity) to promote turbulence

Comparison of the Three Major Fuels

Coal Oil Natural Gas

Installation is expensive Installation is simple Installation is simple

Can be stored in large storage capacity

Storage capacity depends on refinery

No storage

Radiant flame Radiant flame Non-radiant flame

Ash can be used as a raw material

n/a n/a

Cheap Expensive Expensive

Noisy and dirty Depend on refinery Clean

Risk of explosion and fire n/a Flame control reacts

Quality can vary (% H2O & Ash)

Quality is constant Quality is constant

COMBUSTION REACTIONS

Combustibles Reactions Heat Released

Carbon C + O2 = CO2 C + ½ O2 = CO

14650 Btu/lb 4340 Btu/lb

Hydrogen 2H + ½ O2 = H2O 62100 Btu/lb

Sulfur S + O2 = SO2 4032 Btu/lb

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Non-Combustibles (Ash)

It must be treated as a raw material in raw mix

Silica (SiO2)

Alumina (Al2O3)

Iron (Fe2O3)

BASIC PRINCIPLES

SYSTEM OF UNITS

The fundamental quantities to be measured are;

Length

Mass

Time

Temperature

All other quantities that need to be measured can be expressed in terms of above quantities.

Kiln Operation

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Transcript of Kiln Operation